Download PPC-2000 User's Guide

PPC-2000
User’s Guide
WATLOW
1241 Bundy Boulevard
Winona, Minnesota USA 55987
Phone: +1 (507) 454-5300,
Fax: +1 (507) 452-4507
Part No. 0600-3000-2000 Rev 2.3d
http://www.watlow.com
PPC-2000 Adaptive Control
Addendum
Scope
This document describes the additional features and functionality found
in the PPC-2010-xxB with adaptive control. Refer to the PPC-2000
User’s Guide regarding all other functionality which is the same as the
standard version.
Introduction
The Watlow Anafaze PPC-2000 controller offers these standard options:
•
Forty-eight loops of conventional PID control with auto-tuning
capability
-or-
•
Eight loops of adaptive control plus 24 loops of conventional PID
control with auto-tuning for a total of 32 loops (the option described
in this document)
ANAWIN3 HMI software is available to support either option. A mix of
these options is not supported by ANAWIN3.
ANAWIN3 Software Installation
Follow the standard instructions to install and setup ANAWIN3. In the
setup program select the Adaptive Control option.
Spreadsheet Overview Screen
Several new parameters and options appear on the Spreadsheet Overview
screen in support of the adaptive control option. These parameters and
options are applicable only for the first eight channels and are omitted or
ignored for channels 9 to 32.
Control Type
An additional option appears for Control Type. Select Adaptive to enable
adaptive control and tuning on a channel. This option is only valid for
channels 1 to 8.
Values: PID1 (0), PID2 (1), Adaptive (2) and Retransmit (3)
Default: PID1 (0)
Modbus Address (Channels 1 to 32): 46401 to 46432
Parameter Number: 19
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 19.1 to 19.32
Adaptive Addendum
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Adaptive Mode
When Control Type is set to Adaptive, this parameter can be used to
pause tuning or to reset the adaptive algorithm and have it relearn the
system. This parameter has no effect on control if the Control Type for
the loop is set to an option other than Adaptive.
Values: Adapt (0), Reset (1) and Hold (2)
Default: Reset (1)
Modbus Address (Channels 1 to 32): 49001 to 49032
Parameter Number: 21
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 21.1 to 21.32
Table 1. Adaptive Mode Settings
Setting
Adapt
Reset
Hold
Description
The normal setting for a loop with Control Type set to
Adaptive. The loop is adapting and tuning while controlling.
Select this option to have the control loop start from scratch
and relearn the load characteristics. The Control Mode must
be set to Off or Manual to select this option for an adaptive
loop. This is the normal setting for a loop with Control Type
set to a value other than Adaptive.
Select this option to have the control loop stop learning
temporarily but retain the learned load characteristics. For
example in the event that maintenance will be performed, it
may be advantageous to pause adapting to avoid false data
being introduced. Select this option anytime you want the
controller to stop adapting and continue to control with the
parameters learned up to that point.
Plant Delay
This parameter indicates the amount of delay in seconds in the load. This
characteristic of the load or plant has a significant impact on adaptive
control. A larger number indicates a longer delay between, for example
an increase in heater power and an increase in the temperature.
Choose Automatic and then set the Control Mode to Auto to have the
adaptive algorithm determine the plant delay for the loop. The loop must
be at least 40 degrees below set point and the controller must observe a
temperature change of at least 20 degrees to determine the Plant Delay.
If you have determined the Plant Delay with the PPC-2000's adaptive
control previously and found the performance acceptable, you may
choose the delay directly and the loop will use the value you choose
rather than measure it.
This setting is not reset by the Adaptive Mode parameter's Reset option.
To have the controller relearn the Plant Delay, set the loop's Control
Mode to Manual or Off, set the Plant Delay to Automatic, and then set
the Control Mode to Auto again.
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This parameter has no effect on control if the Control Type for the loop is
set to an option other than Adaptive.
Values: Automatic (0) and 1 (1) to 600 seconds (600)
Default: Automatic (0)
Modbus Address (Channels 1 to 32): 49051 to 49082
Parameter Number: 28
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 28.1 to 28.32
Tuning Gain
This parameter indicates the amount of delay in seconds in the load. This
characteristic of the load or plant has a significant impact on adaptive
control. A larger number indicates a longer delay between, for example
an increase in heater power and an increase in the temperature.
Values: Aggressive (0), Nominal (1), Damped 1 (2), Damped 2 (3),
Damped 3 (4) and Damped 4 (5)
Default: Nominal (1)
Modbus Address (Channels 1 to 32): 46551 to 46682
Parameter Number: 29
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 29.1 to 29.32
Figure 1. The Effect of Tuning Gain on Recovery from a
Load Change
Using Adaptive Control
To set up adaptive control on one or more channels:
1. Open the Spreadsheet Overview screen in ANAWIN3.
2. On the Inputs spreadsheet for each analog input you have wired:
a. Choose the appropriate Input Type for the sensor.
b. Choose Units.
c. For any linear voltage, current, or pulse sensors, set the linear
scaling parameters (Input Signal Lo, Input Signal Hi, PV Lo,
and PV Hi). See Setting up User Selectable Linear Inputs on
page 98 of the PPC-2000 User's Guide.
3. On the Channels spreadsheet for each channel:
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a. In the PV Source field, choose the input that you want to
monitor or use as feedback for closed-loop control.
b. In the Heat Output Dest and/or Cool Output Dest fields,
choose the outputs that you want to use for closed-loop control.
c. Choose a Heat/Cool Output Type for each output.
d. Set the Heat/Cool Cycle Time for any outputs with Heat/ Cool
Output Type set to Time Prop.
4. On the Digital I/O spreadsheet:
a. Set the Direction for each I/O point to be used for control to
Output.
5. On the Channels spreadsheet:
a. For channels other than the adaptive ones, if both heat and cool
outputs are used, set the Spread.
b. For each channel that will perform adaptive control, for the
Control Type, choose Adaptive.
c. Set the Set Point to the desired value at least 40 engineering
units (typically degrees) above the process variable.
d. Set the Control Mode to Auto to begin adaptive closed-loop
control.
NOTE: Only channels 1 to 8 can be selected for adaptive control.
Adaptive Addendum
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PPC-2000 User's Guide
Addendum
Overview
This document contains additional specifications for the PPC-2000 system.
Environmental Specifications
Table 1 here contains specifications in addition to those found in tables 7.4, 7.15, 7.23,
7.31, 7.39, 7.46, 7.52, 7.57, 7.62, 7.67 in the PPC-2000 User's Guide.
TABLE 1. Environmental Specifications
Altitude
Non-Condensing Humidity
Relative Humidity
Pollution Category
Operating Temperature Range
Storage Temperature Range
2000 meters max
10 to 95%
80% max (ambient temperature <= 31° C)
50% max (ambient temperature = 40° C)
Degree 2 (per IEC 664)
0 to 60° C (32 to140° F)
-20 to 70° C (-4 to 158° F)
PPC IPS International Power Supply Specifications
Table 2 here contains specifications in addition to those found in table 7.75 in the PPC2000 User's Guide.
TABLE 2. Power Specifications
Input (Mains Supply)
Voltage Fluctuation
88 to 132 Vac (120 Vac nominal)
176 to 264 Vac (240 Vac nominal)
< +10% of nominal voltage
Transient Over-Voltage
Category II per IEC 664
Output
V1: +5 Vdc @ 6 A
V2: +24 Vdc @ 4 A
47 to 440 Hz
9A @ 5Vdc
6A @ 24 Vdc
Input Frequency
Peak Current Output
1241 Bundy Blvd.
Winona, MN 55987
Phone: (507) 494-5656
Fax: (507) 452-4507
©2004 Watlow
Page 1 of 1
Copyright © 1998-2002
Watlow Anafaze
Information in this manual is subject to change without notice. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form without written permission
from Watlow Anafaze.
Warranty
Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be
free from defects in material and workmanship for a period of three years from the date of shipment. The Customer shall provide notice of any defect to Watlow Anafaze, Incorporated within one
week after the Customer's discovery of such defect. The sole obligation and liability of Watlow
Anafaze, Incorporated under this warranty shall be to repair or replace, at its option and without
cost to the Customer, the defective product or part.
Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be defective shall
immediately be returned at the Customer's expense to Watlow Anafaze, Incorporated. Replaced or
repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze,
Incorporated.
There shall be no warranty or liability for any products or parts that have been subject to misuse,
accident, negligence, failure of electric power or modification by the Customer without the written
approval of Watlow Anafaze, Incorporated. Final determination of warranty eligibility shall be
made by Watlow Anafaze, Incorporated. If a warranty claim is considered invalid for any reason,
the Customer will be charged for services performed and expenses incurred by Watlow Anafaze,
Incorporated in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original warranty period, the warranty
period for the replacement or repaired part shall terminate with the termination of the warranty
period of the original product or part.
The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated and the Customer's sole remedy with respect to the products. It is in lieu of all other warranties, liabilities, and
remedies. Except as thus provided, Watlow Anafaze, Inc. disclaims all warranties, express or
implied, including any warranty of merchantability or fitness for a particular purpose.
Please Note: External safety devices must be used with this equipment.
Table of Contents
Table of Contents iii
List of Figures ix
List of Tables xv
Overview 1
Manual Contents 1
Getting Started 2
Safety symbols 2
Contacting Watlow Anafaze 2
Initial Inspection 2
Product Features 3
System Components 3
PPC-2000 Modules 6
PPC-2000 Terminal Boards 8
Additional Components 9
Safety 9
External Safety Devices 10
External Switch Disconnect 11
Battery Safety 11
Product Markings and Symbols 11
Hardware Installation 13
Power Supply Requirements 13
Mounting the Power Supply 15
Hardware Configuration 17
Module Addresses 17
PPC-2010 Jumper Settings 18
PPC-2030 Dip Switch Settings 19
PPC-2030 Jumper Settings 20
PPC-2040 Jumper Settings 21
PPC-205x Jumper Settings 22
Module Disassembly 26
Mounting Modules 26
DIN Rail Mounting 27
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PPC-2000 User’s Guide
Mounting Terminal Boards 28
DIN Rail Mounting 31
DIN Rail Removal 32
Panel Mounting 33
System Wiring 34
Wiring Recommendations 35
Noise Suppression 35
Avoiding Ground Loops 37
Connecting I/O to the PPC-2010 37
Connecting the TB50 to the PPC-2010 Module 37
TB50 Connections 38
Connecting Digital Inputs 40
Connecting Counter or Frequency Inputs 41
Connecting Digital Outputs 41
SDAC Connections 43
Connecting Analog Inputs to the PPC-2021 — 2025 45
Connecting the AITB to the PPC-202x 45
Sensor Keys 46
AITB Connections 47
Connecting Thermocouples 49
Connecting RTDs 50
Connecting Sensors with Linear Voltage Signals 52
Connecting Sensors with Linear Current Signals 53
Connecting the Encoder Input Cable to the PPC-2030 55
Encoder Wiring 57
Encoder Connections without the EITB 59
Analog Output Connections 60
Connecting I/O to the PPC-2040 61
Connecting the TB50 to the PPC-2040 Module 61
TB50 Connections 62
Connecting Digital Inputs 64
Connecting Counter or Frequency Inputs 64
Connecting Digital Outputs 65
Connecting to the Relay Outputs on the PPC-206x 70
Wiring PPC-2062 Relay Outputs 71
Using Snubbers for Relay Outputs 73
Connecting Power 77
PPC-IPS-2 Power Supply 77
Processor Module 77
Connecting Communication Ports 78
Communication Ports 78
Connecting RS-485 Communications 81
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Table of Contents
Operating with AnaWin3 89
Type Definitions 89
Closed-Loop Control 89
Feedback 90
Control Algorithm 90
Control Output Signal Forms 90
Heat and Cool Outputs 90
Prerequisites 93
Background 93
Using AnaWin3 to Tune 94
Alarms 95
Failed Sensor Alarms 95
Global Alarm 95
Process Alarms 95
Alarm Delay 96
Setting up Process and Deviation Alarms 97
Setting Input Signal Lo and Input Signal Hi 99
Setting Engineering Units 99
Setting PV Lo and PV Hi 99
Setting Decimal Places 100
Linear 4-20mA Input Example 101
Process Variable Retransmit 102
Setting up Process Variable Retransmit 103
Process Variable Retransmit Example 104
Cascade Control 105
Setting up Cascade Control 106
Cascade Control Example 106
Ratio Control 109
Setting up Ratio Control 110
Differential Control 112
Remote Set Point 112
Logic Programs 112
Setting up Outputs for Use with a Logic Program 113
Using Logic to Set an Analog Input 113
Starting and Stopping Logic Programs 113
Controller Parameters 115
Channels 115
Digital I/O 132
Soft Integer 136
Soft Boolean 137
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PPC-2000 User’s Guide
Troubleshooting 141
General Description 141
PPC-2010 Processor 141
Processor Module LEDs 147
PPC-2040 Digital I/O 151
PPC-207x Digital In 153
Troubleshooting and Corrective Actions 154
Digital Inputs and Outputs 154
Process Variable 154
Communications 155
Resetting Closed-Loop Control Parameters 156
Disabling Control 157
LogicPro and Modbus Reference 159
Overview 159
Text Conventions in the Database Sections 159
The PPC-2000 Database 160
Data Table Organization 161
How LogicPro Accesses the Database 162
Analog and Counter Input Parameters in the Database 163
Accessing Analog and Counter Input Parameters with Modbus 163
Accessing Analog and Counter Input Parameters with LogicPro 163
Analog Input Numbers and Address Offsets 164
Analog and Encoder Input Parameters 168
Channel Parameters in the Database 172
Accessing Channel Parameters with Modbus 172
Accessing Channel Parameters with LogicPro 173
Channel Parameters for Heat and Cool Outputs 173
Channel Parameters 173
State and Logic 195
Accessing Digital I/O Parameters with Modbus 195
Digital I/O Numbers and Address Offsets 196
Digital I/O Parameters 200
Accessing Analog Outputs with Modbus 202
Accessing Analog Outputs with LogicPro 202
Analog Outputs and Modbus Addresses 202
Analog Output Value 204
Soft Bool and Soft Int Registers in the Database 205
Accessing Soft Bool and Soft Int Registers with Modbus 205
Accessing Soft Bool and Soft Int Registers with LogicPro 205
Soft Bool and Soft Int Registers 205
Global Parameters in the Database 206
Accessing Global Parameters with Modbus 206
Communications Parameters 207
Global Database Parameters 209
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Table of Contents
Tuning and Control 219
Introduction 219
Control Algorithms 220
On/Off Control 220
Output Control Forms 224
Output Filter 225
Proportional Band (PB) Settings 226
Integral Settings 226
Derivative Settings 227
General PID Constants by Application 228
Proportional Band Only (P) 228
Proportional with Integral (PI) 228
PI with Derivative (PID) 228
Specifications 229
System Specifications 229
Safety and Agency Approvals 229
Physical Specifications 230
Power Specifications 230
PPC-2010 Processor Specifications 231
PPC-205x Analog Out Specifications 247
PPC-206x Digital Output Specifications 250
PPC-207x Digital In Specifications 253
PPC-EITB-1 Encoder Input Terminal Block Specifications 258
PPC-TB50-SCSI, 50-Pin Specifications 261
SDAC Specifications 265
Inputs 266
Analog Outputs 267
Appendix A: Modbus Protocol 269
Query 270
Response 270
Message Framing 271
Address Field 272
Function Field 272
Data Field 273
Error Checking Field 273
Field Format 273
Parity Checking 274
CRC Checking 275
Read Examples 280
Appendix B: Declaration of Conformity 283
Glossary 285
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PPC-2000 User’s Guide
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List of Figures
Overview 1
Figure 1.1—System Diagram 4
Figure 1.2—Sample PPC-2000 System
6
Hardware Installation 13
Figure 2.1—PPC-IPS-2 DIN Mounting Dimensions 15
Figure 2.2—PPC-IPS-2 Panel Mounting Dimensions 16
Figure 2.3—Sample Addresses 17
Figure 2.4—PPC-2010 Jumpers 19
Figure 2.5—PPC-2030 Jumpers and Switches 20
Figure 2.6—PPC-2040 Jumper Settings 21
Figure 2.7—PPC-205x Jumpers 23
Figure 2.8—Assembled Modules Top View 24
Figure 2.9—Assembled Modules Bottom View 25
Figure 2.10—Modules Bottom/Side View 25
Figure 2.11—DIN Rail Latches 27
Figure 2.12—Mounting Assembled PPC Modules on a DIN rail (side) 27
Figure 2.13—AITB Dimensions / Clearances 29
Figure 2.14—EITB Dimensions / Clearances 30
Figure 2.15—TB50 Dimensions / Clearances 31
Figure 2.16—TB50 Mounted on DIN Rail (Front) 32
Figure 2.17—TB50 Mounted on DIN Rail (Side) 32
Figure 2.18—TB50 Panel Mounted 33
Figure 2.19—SDAC Dimensions 34
Figure 2.20—PPC-2010 Connection to TB50 38
Figure 2.21—Wiring Digital Inputs 41
Figure 2.22—Encoder with 5Vdc TTL Signal 41
Figure 2.23—Powering Output with 5Vdc from PPC Supply 42
Figure 2.24—Powering Output with 12-24Vdc from PPC supply 42
Figure 2.25—Powering Output with Separate Power Supplies 42
Figure 2.26—Recommended circuitry for CPUWatchdog 43
Figure 2.27—Wiring Single/Multiple SDACs 44
Figure 2.28—PPC-2021 — 2025 Connection to AITB 45
Figure 2.29—Inserting Sensor Keys in AITB 46
Figure 2.30—An Input Key 47
Figure 2.31—Thermocouples Connected to Differential Inputs 1 and 2 49
Figure 2.32—Thermocouples Connected to Single-ended Inputs 1 and 2 50
Figure 2.33—Wiring 2-Wire RTDs: Input 1 and 2 Shown 51
Figure 2.34—Wiring 3-Wire RTDs: Input 1 and 2 Shown 51
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PPC User’s Guide
Figure 2.35—Connecting Linear Voltage Signals to Differential Inputs 1 and 2 52
Figure 2.36—Connecting Linear Voltage Signals to Single-ended Inputs 1 and 2 53
Figure 2.37—Connecting Current Inputs to a Differential Input Module:
Input 1, 2, and 3 Shown 53
Figure 2.38—Connecting Current Inputs to a Single-ended Analog Input
Module: Input 1 and 2 Shown 54
Figure 2.39—PPC-2030 Connections (Bottom View) 55
Figure 2.40—PPC-EITB-1 56
Figure 2.41—EITB Single-ended Single Phase Connections: Input 1 and 2 Shown 57
Figure 2.42—EITB Single-ended Quadrature Connections: Input 1 and 2 Shown 58
Figure 2.43—EITB Differential Single Phase Connections: Input 1 and 2 Shown 58
Figure 2.44—EITB Differential Quadrature Connections: Input 1 and 2 Shown 59
Figure 2.45—PPC-2030 Analog Out Terminal Block 60
Figure 2.46—Analog Output Connections on a PPC-2030: Outputs 1 and 2 Shown 61
Figure 2.47—PPC-2040 Connection to TB50 62
Figure 2.48—Wiring Digital Inputs 64
Figure 2.49—Single Phase Connections: Input 1 and 2 Shown 64
Figure 2.50—Quadrature Connections: Inputs 1 and 2 Shown. 65
Figure 2.51—Powering Output with 5Vdc from PPC Supply 65
Figure 2.52—Powering Output with 12-24Vdc from PPC supply 66
Figure 2.53—Powering Output with Separate Power Supplies 66
Figure 2.54—PPC-205x Connections (Bottom View) 67
Figure 2.55—Analog Output Connections on a PPC-2050 Configured for Current:
Outputs 1 and 2 Shown 68
Figure 2.56—Analog Output Connections on a PPC-2050 Configured for Voltage:
Outputs 1 and 2 shown 69
Figure 2.57—Analog Output Connections on a PPC-2051 Configured for Current and
Voltage: Outputs 1 and 2 shown 69
Figure 2.58—PPC-206x Connections (bottom view) 70
Figure 2.59—Relay Output Connections on a PPC-2061:
Outputs 1, 2, 9 and 10 shown 71
Figure 2.60—Relay Output Connections on a PPC-2062: Outputs 1 and 2 Shown 72
Figure 2.61—Snubber Connections 73
Figure 2.62—PPC-207x Connections (bottom view) 74
Figure 2.63—Input Connections to a PPC-2070 or PPC-2072:
Inputs 1 and 2 shown 74
Figure 2.64—Input Connections to a PPC-2071 or PPC-2073:
Inputs 1,2, 9 and 10 Shown 75
Figure 2.65—Connecting a Current Sinking Field Device to a PPC-2072 or PPC-2073:
Input 1 Shown 75
Figure 2.66—Connecting a Current Sourcing Field Device to a PPC-2072 or
PPC-2073: Input 1 Shown 76
Figure 2.67—PPC-IPS-2 Power Connections 78
Figure 2.68—RS-232 and RS-485 RJ-Type Connectors 79
Figure 2.69—Connecting One PPC to a Computer Using RS-232 81
Figure 2.70—Connecting Multiple PPCs to a Computer Using RS-485 81
Figure 2.71—RS-485 Wiring 82
Figure 2.72—Two Wire RS-485 Wiring 84
Figure 2.73—Connecting Several PPCs with Short Cable Runs 84
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List of Figures
Operating with AnaWin3 89
Figure 3.1—Sample Screen Text 89
Figure 3.2—Process Variable Alarms 96
Figure 3.3—Linear Input Example 98
Figure 3.4—Linear Scaling of the Analog Input for Retransmit on the Heat or Cool
Output 102
Figure 3.5—Sample Application Using Process Variable Retransmit 104
Figure 3.6—How the Secondary Channel’s Set Point is Determined When the
Primary Channel Has Heat and Cool Outputs 105
Figure 3.7—How the Secondary Channel’s Set Point is Determined When the Primary
Channel Has Only a Heat Output 106
Figure 3.8—Sample Application Using Cascade Control 107
Figure 3.9—The Secondary Channel’s Set Point is Determined by the Primary
Channel’s Process Variable 109
Figure 3.10—Relationship between the Master Channel’s Process Variable and the
Ratio Channel’s Set Point. 110
Figure 3.11—Sample Application Using Ratio Control 111
Figure 3.12—Channels Spreadsheet 115
Figure 3.13—Output Scaling (Heat/Cool) Curves 121
Figure 3.14—Alarms Spreadsheet 123
Figure 3.15—Inputs Spreadsheet 127
Figure 3.16—Analog Input Names 127
Figure 3.17—Pulse Input Names 128
Figure 3.18—Soft Input Names 128
Figure 3.19—Channel Output Names 129
Figure 3.20—Dig I/O Spreadsheet 132
Figure 3.21—PPC-2010 and PPC-204X Digital I/O Names 133
Figure 3.22—PPC-206X and PPC-207X Digital I/O Names 133
Figure 3.23—Outputs Spreadsheet 135
Figure 3.24—Analog Output Names 135
Figure 3.25—Soft Int Spreadsheet 136
Figure 3.26—Soft BOOL Spreadsheet 137
Figure 3.27—PPC Globals Screen 138
Troubleshooting 141
Figure 4.1—Assembled Modules Top View 143
Figure 4.2—Assembled Modules Bottom View 143
Figure 4.3—PPC-2010 Internal View 144
Figure 4.4—PPC Assembled Modules Top View 145
Figure 4.5—PPC Assembled Modules Bottom View 146
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List of Figures
PPC User’s Guide
LogicPro and Modbus Reference 159
Figure 5.1—Sample Text 160
Figure 5.2—Output Scaling Curves
185
Tuning and Control 219
Figure 6.1—On/Off Control 220
Figure 6.2—Proportional Control 221
Figure 6.3—Proportional and Integral Control 222
Figure 6.4—Proportional, Integral and Derivative Control 223
Figure 6.5—Example Time Proportioning and Distributed Zero Crossing
Waveforms 224
Specifications 229
Figure 7.1—System Footprint 230
Figure 7.2—PPC-2010 Front View 231
Figure 7.3—PPC-2010 Bottom View 232
Figure 7.4—PPC-2021 Front View 236
Figure 7.5—PPC-2021 - 2025 Bottom View 236
Figure 7.6—PPC-2030 Front View 240
Figure 7.7—PPC-2030 Bottom View 241
Figure 7.8—PPC-2040 Front View 244
Figure 7.9—PPC-2050 Front View 247
Figure 7.10—PPC-2050 Bottom View 248
Figure 7.11—PPC-206x Front View 250
Figure 7.12—PPC-206x Bottom View 251
Figure 7.13—PPC-2070, PPC-2071 Front Views 253
Figure 7.14—PPC-207x Bottom Views 254
Figure 7.15—PPC-AITB-1 256
Figure 7.16—PPC-AITB Dimensions with Straight SCSI Cable 257
Figure 7.17—PPC-EITB-1 258
Figure 7.18—PPC-EITB Dimensions with HD-Type Cable 260
Figure 7.19—PPC-TB50-SCSI Dimensions 261
Figure 7.20—PPC-TB50-SCSI Dimensions with Straight SCSI Cable 262
Figure 7.21—PPC-TB50-SCSI Dimensions with Right-Angle SCSI Cable 263
Figure 7.22—PPC-IPS-2 264
Figure 7.23—SDAC Dimensions 266
Appendix A: Modbus Protocol 269
Figure A.1—Query—Response Cycle
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List of Tables
Overview 1
Table 1.1—PPC-2000 System Modules 5
Table 1.2—PPC-2000 Terminal Boards and Peripheral Modules
Table 1.3— Analog Terminal Board Keys 5
5
Hardware Installation 13
Table 2.2—Power Supply Current Requirements at 24Vdc 14
Table 2.3—Power Supply Screw Mounting 16
Table 2.4—System Modules and Addressing 18
Table 2.5—PPC-2010 Processor Module Jumpers 18
Table 2.6—PPC-2030 Analog Output Jumpers 21
Table 2.7—PPC-2040 Counter Input Jumpers 21
Table 2.8—PPC-205x Analog Out Jumpers 22
Table 2.9—Cable Recommendations 35
Table 2.10—Processor Module I/O Connections 39
Table 2.11—Sensor Keys 46
Table 2.12—Numbers and Types of Inputs by Module Type 47
Table 2.13—Sensor Connections to the AITB 48
Table 2.14—Power Connections on AITB 49
Table 2.15—Encoder Connections to the EITB Connected to J3 on the PPC-2030 56
Table 2.16—Encoder Connections to the EITB Connected to J4 on the PPC-2030 56
Table 2.17—Power Connections on EITB 57
Table 2.18—HD-15 Encoder Signal Connections 59
Table 2.19—HD-15 Power Connections 60
Table 2.20—Analog Output Connections on Encoder In Analog Out Module 60
Table 2.21—Digital I/O Module Connections 63
Table 2.22—Analog Output Connections on Analog Out Module 67
Table 2.23—Relay Output Connections on PPC-206x Digital Output Modules 72
Table 2.24—Digital Input Connections on PPC-207x Modules 76
Table 2.25—PPC-IPS-2 Voltage Input Switch Settings 77
Table 2.26—Power Supply Connections 77
Table 2.27—RS-232 Connector Pin Outs 79
Table 2.28—RS-485 Connector Pin Out and Connections 80
Table 2.29—RTS/CTS Pins in DB-9 and DB-25 Connectors 80
Table 2.30—485 Terminal Block Pin Assignment 83
Table 2.31—PPC-2010 Rotary Switch Configuration 86
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List of Tables
PPC User’s Guide
Operating with AnaWin3 89
Table 3.1—Control Types PID1 and PID2 91
Table 3.2—Alarm Types 95
Table 3.3—Range and Sensitivity of theCustom Linear Input Types 99
Table 3.4—PV Range permitted for various Decimal Places Settings 100
Table 3.5—Scaling Parameters for 0-10Vdc Linear Input Example 101
Table 3.6—Scaling Parameters for 4-20mA Linear Input Example 101
Table 3.7—Scaling Parameters for 0-1Vdc Linear Input Example 102
Table 3.8—Retransmit Channel Parameter Settings 104
Table 3.9—Primary Channel Parameter Settings 107
Table 3.10—Secondary Channel Parameter Settings 108
Table 3.11—Ratio Channel Parameter Settings 111
Table 3.12—AnaWin3 Control Types 118
Table 3.14—Module Abbreviations Seen on the Inputs Spreadsheet 127
Table 3.16—Units 131
Table 3.18—Function Values 134
Table 3.19—Module Abbreviations Seen on the Outputs Spreadsheet 135
Table 3.20—System Status 139
Table 3.21—Global Settings 139
LogicPro and Modbus Reference 159
Table 5.1—Parameter Names & Abbreviations 159
Table 5.2—Example Database Table 160
Table 5.3—Addresses for Analog Inputs on the PPC-202x Modules 164
Table 5.4—Addresses for Encoder Inputs on the PPC-2030 Encoder In Analog Out
Module 165
Table 5.5—Addresses for Counter Inputs on the PPC-2010 Processor Module 166
Table 5.6—Addresses for Soft Inputs and Channel Outputs 166
Table 5.7—Addresses for Encoder Inputs on the PPC-2040 Digital I/O Modules 167
Table 5.8—Input Parameters 168
Table 5.9—Input Status 169
Table 5.11—Temperature Scale Conversion 171
Table 5.13—Process Variable and Setpoint Source Settings for Analog Inputs on the
PPC-202x Modules 176
Table 5.16—Process Variable and Setpoint Source Settings for Soft Input and
Channel Out Registers 178
Table 5.18—Control Mode 180
Table 5.19—Control Types 181
Table 5.21—Heat/Cool Curve 184
Table 5.22—Output Destinations for Digital Outputs on the PPC-2010 Module 186
Table 5.26—Output Destinations for Analog Outputs on the PPC-205x Modules 189
Table 5.27—Output Destinations for Soft Boolean and Soft Integers 190
Table 5.28—Alarm Status 190
Table 5.30—Alarm and Control Functionality 192
Table 5.31—Alarm Acknowledge 192
Table 5.32—Alarm Enable/Disable 192
Table 5.33—Database Offsets and Sample Modbus Addresses for Digital I/O 196
Table 5.37—Digital I/O Uses 200
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List of Tables
Table 5.38—Digital I/O Parameters 200
Table 5.39—State and Logic 201
Table 5.40—Direction 201
Table 5.41—Logic 201
Table 5.44—Soft Bool and Soft Int Parameters 205
Table 5.45—Soft Bool Values 205
Table 5.46—Soft Bool and Soft Int Registers 206
Table 5.47—Rotary Switch Configuration 207
Table 5.48—Communications Parameters 208
Table 5.49—Database Offsets for Baud Rate 208
Table 5.50—Baud Rate 208
Table 5.51—System HW Parameters 209
Table 5.52—Miscellaneous System Parameters 209
Table 5.54—Zero Reference Readings 210
Table 5.55—Ambient Temperature Readings 211
Table 5.56—Modules Present 211
Table 5.57—Module Types 212
Table 5.59—System Status 214
Table 5.60—System Status Bits 214
Table 5.63—Real Time Clock Format 218
Tuning and Control 219
Table 6.1—Proportional Band Settings 226
Table 6.2—Integral Term and Reset Settings
Table 6.3—Derivative Term vs. Rate 227
Table 6.4—General PID Constants 228
227
Specifications 229
Table 7.1—Safety and Agency Approvals 229
Table 7.2—PPC System Dimensions 230
Table 7.3— Model Number 232
Table 7.4—Environmental Specifications 232
Table 7.5—Physical Specifications 232
Table 7.7—Power Specifications 233
Table 7.8—Capacity and Programming 233
Table 7.9—Control Specifications 234
Table 7.10—Counter/Frequency Input Specifications 234
Table 7.11—Digital Input Specifications 234
Table 7.12—Digital Output Specifications 235
Table 7.13—Serial Interface 235
Table 7.14—Model Numbers 237
Table 7.15—Environmental Specifications 237
Table 7.16—Physical Specifications 237
Table 7.17—Connections 237
Table 7.18—Power Specifications 237
Table 7.21—Sensor Reference Voltage Output 239
Table 7.22—Model Number 241
Table 7.23—Environmental Specifications 241
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List of Tables
PPC User’s Guide
Table 7.24—Physical Specifications 241
Table 7.25—Connections 242
Table 7.26—Power Specifications 242
Table 7.27—Input Specifications 242
Table 7.29—Safety and Agency Approvals 243
Table 7.30—Model Number 244
Table 7.31—Environmental Specifications 244
Table 7.32—Physical Specifications 245
Table 7.33—Connections 245
Table 7.34—Power Specifications 245
Table 7.35—Counter/Frequency Specifications 245
Table 7.37—Digital Output Specifications 246
Table 7.38—Model Number 248
Table 7.39—Environmental Specifications 248
Table 7.40—Physical Specifications 248
Table 7.41—Connections 249
Table 7.42—Power Specifications PPC-2050 249
Table 7.43—Power Specifications PPC-2051 249
Table 7.44—Output Specifications 249
Table 7.45—Model Number 251
Table 7.46—Environmental Specifications 251
Table 7.47—Connections 251
Table 7.48—Physical Specifications 252
Table 7.49—Power Specifications 252
Table 7.50—Output Specifications 252
Table 7.51—Model Number 254
Table 7.52—Environmental Specifications 254
Table 7.53—Physical Specifications 254
Table 7.54—Connections 255
Table 7.55—Power Specifications 255
Table 7.56—Digital Input Specifications 255
Table 7.57—Environmental Specifications 256
Table 7.58—Physical Specifications 256
Table 7.59—Connections 257
Table 7.60—PPC-AITB with Straight SCSI 257
Table 7.61—Sensor Key Cards 258
Table 7.62—Environmental Specifications 259
Table 7.63—Physical Specifications 259
Table 7.64—Connections 259
Table 7.65—PPC-EITB with HD-Type Cable 259
Table 7.66—Safety and Agency Approvals 259
Table 7.67—Environmental Specifications 261
Table 7.68—Physical Specifications 261
Table 7.70—PPC-TB50-SCSI with Straight SCSI 262
Table 7.72—Environmental Specifications 264
Table 7.73—Physical Specifications 264
Table 7.74—Dimensions with Din Rail Bracket 265
Table 7.75—Power Specifications 265
Table 7.76—Connections 265
Table 7.77—Safety and Agency Approvals 265
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PPC User’s Guide
List of Tables
Table 7.78—Environmental Specifications 265
Table 7.79—Physical Specifications 266
Table 7.80—Safety and Agency Approvals 266
Table 7.81—Inputs 267
Table 7.82—Power Requirements 267
Table 7.83—Analog Output Specifications 267
Appendix A: Modbus Protocol 269
Table A.1—Example Message Frame 271
Table A.2—Function Codes 276
Table A.3—Sample Packet for Host Query 280
Table A.4—Sample Packet for Slave Response 280
Table A.5—Sample Packet for Host Query 281
Table A.6—Sample Packet for Slave Response 281
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List of Tables
xviii
PPC User’s Guide
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
1
Overview
Manual Contents
This manual describes how to install, set up, and operate a
PPC-2000 controller. Each chapter covers a different aspect of
your control system and may apply to different users. The
following describes each chapter’s purpose.
Doc.# 30002-00 Rev 2.3
•
Chapter 1: Overview. Provides component list and
summary of features for the PPC-2000.
•
Chapter 2: Hardware Installation. Provides detailed
instructions on installing the PPC-2000 system and its
peripherals.
•
Chapter 3: Software Setup. Describes how to use your
PPC system with AnaWin3, the Watlow Anafaze HumanMachine Interface (HMI) software.
•
Chapter 4: Troubleshooting. Includes troubleshooting,
upgrading and reconfiguring procedures for technical
personnel.
•
Chapter 5: Custom Interfacing. Provides information
on setting up third-party software or an operator interface
terminal for operating and monitoring a PPC System. Also
provides information needed to address parameters when
writing programs using LogicPro.
•
Chapter 6: Tuning and Control. Describes available
control algorithms and provides suggestions for
applications.
•
Chapter 7: Specifications. Lists detailed specifications
of the controller and optional components.
Watlow Anafaze
1
Chapter 1: Overview
PPC-2000 User’s Guide
Getting Started
The following sections provide information regarding product
features, system components, safety requirements, and
preparation for operation.
Safety symbols
These symbols are used throughout this manual:
∫
WARNING!
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious
injury.
ç
CAUTION!
Indicates a potentially hazardous situation which, if
not avoided, could result in minor or moderate injury
or property damage.
NOTE!
Indicates pertinent information or an item that may be
useful to document or label for later reference.
Contacting Watlow Anafaze
To contact Watlow Anafaze, send correspondence to:
Watlow Anafaze, Inc.
314 Westridge Drive
Watsonville, CA 95076
Our technical support and customer service departments may
be reached Monday-Friday, 8 a.m. to 5 p.m. Pacific time:
Telephone: +1 (831) 724-3800
Email: [email protected]
Be sure to specify PPC2000 when asking for technical support.
Initial Inspection
Accessories may or may not be shipped in the same container
as the PPC-2010 controller, depending upon their size. Check
the shipping invoice carefully against the contents received in
all boxes.
2
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 1: Overview
Product Features
The PPC-2000 (PPC) offers high performance closed-loop (PID)
control and the ability to manipulate process control
algorithms and sequential logic in a very user friendly way. It
is a modular programmable process control system that utilizes
plug-in modules to meet different system requirements. The
controller can be configured for as many as 48 channels of PID
control and supports up to 288 programmable digital I/O
points. A motor interface module allows for operating up to 16
motor speed control systems. Seven types of hardware modules
are supported by the PPC system. AnaWin3 HMI software is
used for configuration, operation and data acquisition.
LogicPro software is available as an option and can be used to
write logic programs for sequential and process control.
The PPC controller includes the following features:
•
Multiple channels of closed-loop control and
programmable logic in an integrated package
•
User-programmable, advanced control algorithms
•
Modular hardware
•
Bus expansion up to 9 additional modules
•
Serial communication
•
AnaWin3 operator interface compatible (single or multiple
PPC modbus network capability
•
Analog inputs (as many as 128) per PPC system
•
Multiple sensor inputs: multiple TC types, RTD, voltage,
current
•
As many as 288 digital I/O points
•
48 closed-loop control channels with autotune
•
Windows®-based logic programming software (option)
•
Third-party operator interface terminal (OIT) support
(option)
System Components
Any system must include a power supply and a processor
module (PPC-2010) with built-in digital I/O. The appropriate
additional modules are added for analog inputs, analog
outputs, and expanding the digital I/O.
See Figure 1.1 on page 6-4 and Figure 1.2 on page 6-6 for
illustrations of the PPC’s system components and modules.
Refer to Table 1.1 on page 5 for a description of the modules and
their functions.
The number and types of I/O are determined by which modules
are selected for the application. Field wiring connects to DIN
rail or panel mounted terminal block boards. Terminal block
boards connect to I/O modules via 50-pin SCSI cables.
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Watlow Anafaze
3
Chapter 1: Overview
PPC-2000 User’s Guide
The following hardware and software interfaces are provided:
Hardware
•
Serial ports for interfacing host computers and thirdparty operator displays
•
Analog input and output terminal block connections
•
Digital input and output terminal block connections
Software / Firmware
PC for AnaWin3 HMI
Software and/or LogicPro
•
Remote third-party operator interface panel software
using Modbus protocol (option)
•
AnaWin3 Configurator edition: Windows configuration
utility
•
LogicPro: Windows logic programming utility (option)
•
AnaWin3 Developer edition: Windows user interface, data
monitoring and trend logging utility (option)
Power
Supply
PPC-2000
Assembly
Encoder Input
Terminal Block
(EITB)
Analog Input
Terminal Board
(AITB)
TB50 for
Digital I/O
Operator
Interface
Terminal
Figure 1.1
4
System Diagram
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 1: Overview
Table 1.1
PPC-2000 System Modules
Module
Description
PPC-2010
Processor, 48 digital I/O, 2 serial ports,
1 counter/frequency input
PPC-2021, 2022
16 differential or 32 single-ended analog inputs
PPC-2024, 2025
8 or 16 highly isolated analog inputs
PPC-2030
4 encoder inputs and 4 analog outputs
PPC-2040
32 configurable digital I/O, 2 counter/frequency
inputs
PPC-2050
8 analog outputs
PPC-2051
4 analog outputs
PPC-2061
16 relay outputs
PPC-2062
8 relay outputs
PPC-2070, 2071
8,16 120Vac inputs
PPC-2072, 2073
8,16 24V AC/DC inputs
Table 1.2
PPC-2000 Terminal Boards and
Peripheral Modules
Terminal Board
PPC-IPS-2
International Power Supply, 120W
PPC-AITB-1
Analog Input Terminal Board
PPC-TB50-SCSI
Terminal board for digital I/O
PPC-EITB-1
Encoder Input Terminal Board
Table 1.3
Analog Terminal Board Keys
Key
(Color Code)
Doc.# 30002-00 Rev 2.3
Description
Descriptions
PPC-KEY-20
(none)
Adapts AITB for:
Thermocouples (differential or single-ended)
Linear voltages (differential or single-ended)
PPC-KEY-30
(blue)
Adapts AITB for 0-20mA linear current
(differential)
PPC-KEY-40
(black)
Adapts AITB for 0-20mA linear current
(single-ended)
PPC-KEY-50
(red)
Adapts AITB for 2-wire RTDs (differential) or
3-wire RTDs (differential)
Watlow Anafaze
5
Chapter 1: Overview
PPC-2000 User’s Guide
Figure 1.2
Sample PPC-2000 System
PPC-2000 Modules
The following sections describe the purpose and features of
each type of module available with the PPC-2000 system.
PPC-2010 Processor Module
The PPC-2010 processor module houses the system
microprocessor, memory and controller programs. Modular
communication ports support connections with a PC running
AnaWin3 and LogicPro or third-party interface software, and
connections with third-party operator interface panels or other
devices that communicate using Modbus protocol. Communications ports one and two may be used simultaneously.
Additional modules may be connected to the processor module’s
expansion bus to add capabilities to the PPC system.
Precision analog outputs can be provided using Serial Digital to
Analog Converters (SDAC). Each SDAC unit converts a control
output from the processor module to an analog voltage or
current signal. For more specific information, see SDAC Serial
Analog-to-Digital Converter on page 9.
6
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 1: Overview
The PPC-2010 has 48 built-in digital I/O points. 24 points are
outputs only. 22 of these outputs are user configurable for PID
control, alarms or logic outputs. The other 2 outputs are
dedicated to system status and global alarm. The remaining 24
I/O points are individually configurable as either inputs or
outputs.
The following summarizes the processor’s features:
•
2 isolated communication ports
•
Transmit/receive indicators
•
Rotary switch for setting the Modbus network address
•
46 user configurable digital I/O
•
System status and digital output overload indicators
•
Real time clock
•
Flash PROM and battery backed RAM
•
Connects to terminal block board via 50-pin SCSI cable
PPC-2021 - 2022 Analog In Modules
The PPC-2021 and 2022 modules plug in to the module
expansion bus. The analog input modules support 16
differential inputs or 32 single-ended inputs, and accommodate
various sensors such as thermocouples (TCs), Resistive
Temperature Sensing Devices (RTDs) and linear transducers
using the terminal boards described later in this section.
•
Supports TCs, RTDs and linear voltage and current
signals
•
LED status indicator
•
DIN rail/panel mount
•
Connects to analog input terminal board via 50-pin SCSI
cable
PPC-2024 - 2025 Analog In High Isolation Modules
The PPC-2024 and 2025 modules plug in to the module
expansion bus. The high isolation analog input modules accept
8 or 16 differential analog inputs and accommodate various
sensors such as TCs, RTDs and linear transducers using the
terminal boards described later in this section.
Doc.# 30002-00 Rev 2.3
•
High voltage isolation capability
•
Supports TCs, RTDs and linear voltage & current signals
•
LED status indicator
•
DIN rail/panel mount
•
Connects to analog input terminal board via 50-pin SCSI
cable
Watlow Anafaze
7
Chapter 1: Overview
PPC-2000 User’s Guide
PPC-2030 Encoder In Analog Out Module
The PPC-2030 is used in applications including monitoring and
controlling belt speeds, motor speeds, positioning, etc.
Four isolated analog outputs are jumper configurable for
current or voltage. These outputs may be used to provide
software selectable analog output signals to field devices.
Four counter inputs are used for interfacing to motor encoder
signals. The counters interface to both single-ended and
differential styles of encoder signals and count quadrature
signals for increased resolution, accuracy and direction.
PPC-2040 Digital I/O Module
Up to four PPC-2040 modules may be added to a PPC system.
Each module includes 32 digital I/O points which are
individually configurable as inputs or outputs and two counter
and frequency inputs.
PPC-2050 - 2051 Analog Out Modules
Up to four PPC-2050 and PPC-2051 modules may be added to
a PPC system. Modules include four or eight analog outputs.
PPC-2061 - 2062 Digital Out Relays Module
Up to six PPC-2060, PPC-2061, and PPC-2062 modules may be
added to a PPC system. The PPC-2061 features 16
electromechanical relays. These relays can switch AC or DC
loads. Two sets of eight relays each have a common. The PPC2062 features eight electromechanical relays.
PPC-2070 - 2073 Digital In Modules
Up to four modules of this type may be added to a PPC system.
Each module includes either 8 or 16 discrete inputs. The PPC2070 and 2071 modules accept 120Vac signals. The PPC-2072
and 2073 modules accept either 24Vac or 24Vdc.
PPC-2000 Terminal Boards
The following sections describe the terminal boards that
support field I/O connections to some modules.
PPC-AITB-1 Analog Input Terminal Board
The AITB is a compact field wiring interface for all analog
input modules. The AITB includes terminal blocks and
removable keys used for different types of inputs such as TCs,
RTDs and linear signals. For more information on these
signals, refer to PPC-KEY-01 through 04 in Table 1.1 on page
5. The keys allow easy configuration of the terminal block for
different types of inputs on different channels. The AITB is
DIN rail or panel mount compatible.
8
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 1: Overview
PPC-EITB-1 Encoder Input Terminal Board
The EITB is a DIN rail or panel mountable terminal block card
which provides means to interface with motor encoders. Two
pulse inputs (single ended or differential, single or quadrature
phased) may be connected to the screw terminals. A 5Vdc
power source interconnect is provided to supply encoders.
PPC-TB50-SCSI 50-Pin Terminal Board
The TB50 connects to the Processor or Digital I/O module
through the SCSI connector. The terminal blocks interface to
digital I/O field wiring (sensors, actuators, relays, SSRs, etc.).
The TB50 has 48 input/output points. This terminal board is
DIN rail or panel mount compatible.
Additional Components
The following sections describe the optional SDAC module and
the PPC-IPS-2 power supply.
SDAC Serial Analog-to-Digital Converter
The SDAC peripheral module can be connected to a digital
output on the PPC-2010 Processor module. The SDAC converts
a special serial signal to an analog output.
One digital output is required for each SDAC module. Up to 5
SDACS may be connected. When using one or more SDACs, the
SDAC clock output from the PPC-2010 is used as well. The
Processor/SDAC clocks are tied together (the same clock line is
used for each SDAC).
PPC-IPS-2
The PPC-IPS-2 accepts power in two switch-selectable ranges:
88 to 132Vac and 176 to 264Vac at 47 to 440Hz. It has overload
and overvolt protection. The PPC-IPS-2 powers the PPC
system with 24Vdc and has 5Vdc available for powering loads.
Safety
Watlow Anafaze has made every effort to ensure the reliability
and safety of this product. In addition, we have provided
recommendations that will allow you to safely install and
maintain this controller. This product should not be used in any
manner not specified by Watlow Anafaze.
∫
WARNING!
Doc.# 30002-00 Rev 2.3
Ensure that power has been shut off to your entire
process before you begin installation or servicing of
the controller.
Watlow Anafaze
9
Chapter 1: Overview
PPC-2000 User’s Guide
∫
WARNING!
Power, input or output circuits with hazardous
voltage levels should not have any live accessible
parts.
∫
WARNING!
In any application, failures can occur. These failures
can result in full control output (100% power), or the
occurrence of other output failures which can cause
damage to the controller, or to the equipment or
process connected to the controller. Therefore,
always follow good engineering practices, electrical
codes, and insurance regulations when installing and
operating this equipment.
CAUTION: This product is intended for indoor use only.
External Safety Devices
External safety devices should be used to prevent potentially
dangerous and unsafe conditions upon equipment failure.
Always assume that this device can fail with outputs full-on, or
full-off, by the occurrence of an unexpected external condition.
∫
WARNING!
Always install high or low temperature protection in
installations where an over-temperature or undertemperature fault will present a potential hazard.
Failure to install external protection devices where
hazards exist can result in damage to equipment and
property as well as loss of human life.
Contact Watlow Anafaze immediately if you have any
questions about system safety or system operation.
10
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 1: Overview
External Switch Disconnect
∫
WARNING!
Provide a labeled switch or circuit breaker connected
to the PPC-2000 power wiring as the means of
disconnection for servicing. Failure to do so could
result in damage to equipment and/or property, and/
or injury or death to personnel. The disconnect
should be located so that operators and technicians
can access it quickly and easily.
Battery Safety
ç
CAUTION!
The battery used in this device may result in a fire or
chemical burn hazard if mistreated. Do not
disassemble, heat above 100˚C (212˚F) or incinerate.
Dispose of used battery properly. Keep away from
children.
Product Markings and Symbols
This symbol indicates that the products meets the essential
requirements of applicable European Union Directives.
C
US
LISTED
Î
Doc.# 30002-00 Rev 2.3
This symbol indicates that the product is listed by
Underwriters Laboratory and Canadian Underwriters
Laboratory.
The terminals adjacent to this symbol should be connected to
DC voltage only.
Watlow Anafaze
11
Chapter 1: Overview
12
PPC-2000 User’s Guide
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
2
Hardware Installation
This section describes how to install your PPC system
hardware. It provides detailed instructions for each component
and peripheral item. Read this chapter before installing your
PPC-2000 system.
Power Supply Requirements
Watlow Anafaze provides the PPC-IPS2 power supply for the
PPC-2000 system. This unit supplies sufficient current for a
processor and various combinations of I/O modules. For
specification information on the power supply, refer to Chapter
7, Specifications.
Any power supply connected to the PPC-2000 should meet
these requirements:
•
Transformer isolation
•
Reliable operation without noise or feedback
•
Provides specified voltage and current
•
UL Listed
•
Suitable for use in a 60°C ambient environment
Regardless of which power supply you use, you must provide
sufficient current in the specified voltage range, 10-28Vdc. The
current requirement depends on the type and number of
modules used. A separate power supply is required for each
controller. Use Table 2.1 on page 14 to calculate the current
requirements for your system.
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
13
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Table 2.1
Power Supply Current
Requirements at 12Vdc
Module
Number
of
modules
PPC-2010
1
Current
x
250mA
=
PPC-202x
(max. 4)
x
390mA
=
PPC-2030
(max. 4)
x
900mA
=
PPC-2040
(max. 6)
x
300mA
=
x
800mA
=
x
500mA
=
PPC-206x
(max. 6)
x
250mA
=
PPC-207x
(max. 4)
x
100mA
=
total
current
required
=
PPC-2050
PPC-2051
(max. 4)
Total Number of
Modules
(max. 10)
Table 2.2
Module
PPC-2010
250mA
Power Supply Current Requirements
at 24Vdc
Number
of
modules
1
Current
(startup)
per
module
Current
x
125mA
=
PPC-202x (max. 4)
x
195mA
=
PPC-2030 (max. 4)
x
450mA
=
PPC-2040 (max. 6)
x
150mA
=
PPC-2050
PPC-2051
(max. 4)
x
400mA
250mA
=
PPC-206x (max. 6)
x
125mA
=
PPC-207x (max. 4)
x
50mA
=
total
current
required
=
Total Number of
Modules (max. 10)
14
Current
(startup)
per
module
Watlow Anafaze
125mA
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
∫
WARNING!
The PPC is designed to operate on 12-28Vdc.
Connection to a power source other than this will
cause damage to the PPC.
To avoid electrical shock, correctly connect the
power supply’s earth ground.
Mounting the Power Supply
Mount the hardware in an area free of moisture or corrosive
chemicals. Mount the power supply vertically with adequate
vent space. Locate the power supply for the PPC such that the
AC supply and DC connections to the PPC may be made. The
PPC-IPS-2 can be DIN rail or screw mounted. Refer to Figure
2.1 for power supply mounting clearances. All dimensions are
measured in inches.
V1
ADJ
2.5 in. min.
Air Flow Space
V2 COM COM V1 V1
1.2 in.
L
N
3.1 in.
1.97 in.
Figure 2.1
Doc.# 30002-00 Rev 2.3
PPC-IPS-2 DIN Mounting
Dimensions
Watlow Anafaze
15
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
1.97 in.
0.24 in.
1.32 in.
All
Vented
115
7.5 in.
0.10 in.
7.84 in.
0.93 in.
0 79 i
Figure 2.2
PPC-IPS-2 Panel Mounting
Dimensions
To DIN rail mount the PPC-IPS-2:
1.
Locate a space with sufficient room for the power supply
and connecting wires. Refer to Figure 2.1 on page 15.
2.
Install a section of DIN rail.
3.
Hook the top of the DIN rail latch over the DIN rail such
that the spring is under the lip of the rail.
4.
Push down on the power supply, compressing the spring
then rock the bottom of the latch onto the rail.
To panel mount the PPC-IPS-2:
1.
Locate a space with sufficient room for the power supply
and connecting wires. Refer to Figure 2.2.
2.
Mark the mounting holes. See Table 2.3 on page 16.
3.
Drill and tap the mounting holes.
4.
Place the power supply such that the holes are aligned,
insert the screws and tighten them
Table 2.3
Power Supply Screw Mounting
PPC-IPS-2
16
Number of Screws
3
Drill and tap size
#6
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Hardware Configuration
In order for multiple PPC modules to function together, each
needs to be addressed correctly. Some of the PPC modules may
require jumper or switch settings to work with field input and
output devices. The following sections describe the
configuration options and procedures.
Module Addresses
Each module in a PPC assembly must have a unique address.
The PPC-2010 module is fixed as module address 0 in the
firmware. The other modules’ addresses are set with rotary
switches on the face of each module. Set a unique address on
each module by turning the arrow to an appropriate address
number. See Figure 2.3.
Figure 2.3
Sample Addresses
Table 2.4 on page 18 lists the maximum number allowable of
each type of module per system, as well as the available
address settings. Pay close attention when using more than one
module of a particular type in a system. For example, one PPC
system allows up to four analog input modules (PPC-2021 2025) and each must have a unique address setting, as shown
in Figure 2.3.
ç
CAUTION!
If address settings are changes, modules added or
removed after the system has been initialized,
modules may not function correctly. To assure proper
operation, perform a RAM Clear after changing the
number of modules or address settings in a PPC
system. Refer to Chapter 4, Resetting Closed-Loop
Control Parameters on page 156.
NOTE!
It may be useful to label each module with the address
you select.
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17
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Table 2.4
System Modules and Addressing
Module
Max.
#*
Rotary Switch
Address Range
2010 (PROCESSOR)
1
0 (not switch selectable)
2021, 2022
(ANALOG IN)
2023, 2024, 2025
(ANALOG IN
HIGH ISOLATION)
4
1-4
2030
(ENCODER IN
ANALOG OUT)
4
11-14
2040
(DIGITAL I/O)
6
21-26,
2050, 2051
(ANALOG OUT)
4
31-34
2061, 2062
(DIGITAL OUT)
6
41-46
2070, 2071
(DIGITAL IN, 120Vac)
2072, 2073
(DIGITAL IN, 24Vac/DC)
4
51-54
* Maximum number of this type of module in a system
PPC-2010 Jumper Settings
Jumper settings in the PPC-2010 select whether the
communication lines are terminated or not. Each
communication port is configured separately. For installation
information, refer to Connecting RS-485 Communications on
page 81.
Wear a grounding strap and place components on static-free
grounded surfaces only. Locate jumpers 1 and 2. Table 2.5
describes the PPC-2010 jumper configuration. Install the
jumper in the orientation shown in Figure 2.4 on page 19.
Table 2.5
18
PPC-2010 Processor Module Jumpers
Port
Jumper #
Terminated
Position
Unterminated
Position
1
JU1
A
B
2
JU2
A
B
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Flash memory
Chip (firmware)
Battery
Notch
JU1
Termination
Jumper
B A
Notch
B A
JU1
Port 1
JU2
B A
Not Terminated
Position
Figure 2.4
PPC-2010 Jumpers
PPC-2030 Dip Switch Settings
Switch settings in the PPC-2030 determine whether encoder
inputs accept single phase or quadrature encoder signals. Each
of the four inputs is configured individually, therefore single
phase and quadrature inputs may be mixed in a module.
Wear a grounding strap and place components on static-free
grounded surfaces only. Locate switch bank 1 near the center
of the PPC-2030 module. Refer to Figure 2.5 on page 20. Set
each switch for the corresponding input to the single phase (on)
or quadrature (off) position. The switch is on when in the
direction indicated by the arrow.
ç
CAUTION!
Doc.# 30002-00 Rev 2.3
Be sure to take antistatic precautions.
Watlow Anafaze
19
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
{Improve illustration. More like 2.6 and 2.7.}
Counter Input Number
1
2
3
4
51
S1
.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
................
SV4
Single Phase
Quadrature
Analog Output Jumpers
...
...
Figure 2.5
...
...
...
...
JU4
...
...
JU3
v
i
Current
Position
JU2
v
i
Voltage
Position
JU1
...
...
...
...
Dip Switch
JU1 (Output 4)
JU2 (Output 3)
JU3 (Output 2)
JU4 (Output 1)
PPC-2030 Jumpers and Switches
PPC-2030 Jumper Settings
Each of the four analog outputs on the PPC-2030 may be
configured either as a voltage output or a current output. A
mixture of current and voltage outputs may be used on a
particular module. The jumpers only determine if the output
signal is current or voltage. The actual span of the signal is
software selectable. See Output Type in Channels on page 115
for the various analog output signal settings.
Locate Jumpers 1 through 4. Table 2.6 on page 21 describes the
analog output jumper configuration. Install the jumper in the
orientation shown in Figure 2.5.
ç
CAUTION!
20
Incorrectly installing the jumper may damage the
PPC-2030 module.
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Table 2.6
PPC-2030 Analog Output Jumpers
Analog
Output
Jumper #
i (current)
position*
V (volt)
position*
1
JU4
0-20mA
0-10Vdc
2
JU3
0-20mA
0-10Vdc
3
JU2
0-20mA
0-10Vdc
4
JU1
0-20mA
0-10Vdc
* Listed values are maximum ranges. Other ranges within these
limits may be selected in software.
PPC-2040 Jumper Settings
Each of the counter inputs on the PPC-2040 can be configured
for single phase or quadrature input. Jumper positions
determine the counter input configuration. To select single
phase or quadrature, see Table 2.7 and Figure 2.6 to determine
which jumper to set and appropriate position.
Table 2.7
PPC-2040 Counter Input Jumpers
1
JU1
A
B
2
JU2
A
B
Figure 2.6
Doc.# 30002-00 Rev 2.3
JU2
Quadrature
Position
JU1
Single Phase
Position
A B
Jumper
PPC-2040
A B
Counter
Input
PPC-2040 Jumper Settings
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
PPC-205x Jumper Settings
Each of the analog outputs on the PPC-205x modules may be
configured either as a voltage output or a current output. A
mixture of current and voltage outputs may be used on a
particular module. The jumpers only determine if the output
signal is current or voltage. The actual span of the signal is
software selectable. See Heat/Cool Output Type in Channels
section on page 119 for the various analog output signal
settings.
To configure an output, see Table 2.8 on page 22 and Figure 2.7
on page 23 to determine which jumper to set. Set the jumper in
the indicated position and orientation.
Table 2.8
PPC-205x Analog Out Jumpers
Analog
Output
Jumper
PPC-2050
Jumper
PPC-2051
i (current)
Position*
v (voltage)
Position*
1
JU1
JU1
0-20mA
0-10Vdc
2
JU2
JU3
0-20mA
0-10Vdc
3
JU3
JU5
0-20mA
0-10Vdc
4
JU4
JU7
0-20mA
0-10Vdc
5
JU5
n/a
0-20mA
0-10Vdc
6
JU6
n/a
0-20mA
0-10Vdc
7
JU7
n/a
0-20mA
0-10Vdc
8
JU8
n/a
0-20mA
0-10Vdc
* Listed values are maximum ranges. Other ranges within these
limits may be selected in software.
22
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Analog Output Jumpers
JU1
I
V
JU2
I
V
V
I
JU3
JU4
I
V
JU5
I
V
JU6
I
V
JU7
I
V
I
Current
Position
V
Voltage
Position
JU8
I
V
...
...
I
V
...
...
JU8 (2050: Output 8)
JU7 (2050: Output 7, 2051: Output 4)
JU6 (2050: Output 6)
JU5 (2050: Output 5, 2051: Output 3)
JU4 (2050: Output 4)
JU3 (2050: Output 3, 2051: Output 2)
JU2 (2050 Output 2)
JU1 (Output 1)
Figure 2.7
Doc.# 30002-00 Rev 2.3
PPC-205x Jumpers
Watlow Anafaze
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Module Assembly
Modules should be assembled prior to mounting. The processor
module is always the first module (left side) on a PPC system.
To connect other modules, use the following procedure.
ç
CAUTION!
To avoid damaging your PPC system, never connect
or disconnect modules that are powered.
ç
CAUTION!
PPC modules contain sensitive electronic
components. Be sure to observe ESD safety
precautions such as wearing a ground strap.
1.
Make sure the red top and bottom module latches on the
module to be added are in the unlocked position (pushed
toward the back of the module. Refer to Figure 2.8.
Back
Module
top
latch
(unlocked)
Module
top
latch
(locked)
Front
Figure 2.8
24
Assembled Modules Top View
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
2.
Align the 4 interconnect tabs and their related slots, as
well as the module expansion bus connector.
Front
Module
bottom
latch
(locked)
Back
Figure 2.9
Module
bottom
latch
(unlocked)
Assembled Modules Bottom View
Slot
Tab
Module
bottom
latch
(locked)
Module
bottom
latch
(unlocked)
Figure 2.10 Modules Bottom/Side View
Doc.# 30002-00 Rev 2.3
3.
Gently press the modules together while observing the
alignment of the tabs and slots, as well as the pins on the
expansion bus connector.
4.
When the module is properly seated, close the module
latches on the processor by pushing the latch toward the
front of the module. The modules are properly locked when
there is a firm connection with no rocking or shifting.
5.
Repeat these steps for any additional modules. When
there are no additional modules, install the right end cap
in a similar manner.
Watlow Anafaze
25
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Module Disassembly
To separate modules, reverse the procedure in Module
Assembly on page 24. When separating modules, gently rock
and pull the modules apart.
ç
CAUTION!
To avoid damaging your PPC system, never connect
or disconnect modules that are powered.
Mounting Modules
Once the modules have been assembled, the PPC system may
be mounted on a DIN rail or fastened directly to a vertical
surface inside an electrical cabinet or other enclosure that
requires a key or tool to open, or that has a safety interlock
system. Consult Table 7.2 on page 230 and Figure 7.1 on page
230 to determine mounting hole spacing and installed
clearances. See Figure 1.1 on page 4 for a sample configuration
of PPC system hardware.
∫
WARNING!
Install the PPC-2000 in a controlled environment,
relatively free of contaminants, to
reduce the risk of fire or electric shock.
ç
26
CAUTION!
The controller may function incorrectly if the ambient
temperature exceeds the operating specification.
Make sure the air temperature surrounding the
controller does not exceed 140°F (60°C).
NOTE!
During wiring and cabinet assembly, prevent debris
from falling inside the PPC by removing the unit from
the area, or cover the ventilation holes on the PPC
system.
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
DIN Rail Mounting
1.
Each module in the assembly has a DIN rail latch. Pull all
the latches to the open position. See Figure 2.11.
DIN Rail Latch
(closed)
DIN Rail Latch
(open)
Figure 2.11 DIN Rail Latches
2.
Place the module assembly on the upper lip of the DIN
rail; push the lower side of the assembly over the lower lip
of the DIN rail. See Figure 2.12.
Upper lip of
DIN Rail
DIN Rail Latch
(open)
Push to lock
Figure 2.12 Mounting Assembled PPC
Modules on a DIN rail (side)
3.
Doc.# 30002-00 Rev 2.3
Push the DIN rail latches up and under the lower lip of the
DIN rail.
Watlow Anafaze
27
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Panel Mounting
The PPC modules may be panel mounted using the mounting
holes located on the end plates. The width of a system varies
depending on the number of modules. Consult Figure 7.1 on
page 230 to determine installed clearances.
To panel mount the modules:
1.
Locate a space with sufficient room for the appropriate
number of modules and connecting wires. Refer to Figure
7.1 on page 230 for a system footprint and dimensions.
2.
The mounting holes are located on the end caps of the
module assembly. Mark each mounting hole.
3.
Drill and tap the four #10 mounting holes.
4.
Place the modules such that the holes are aligned, insert
the screws and tighten them.
Mounting Terminal Boards
Terminal boards support interfacing field I/O devices with the
PPC modules. All terminal boards may be DIN rail or panel
mounted. The following sections provide procedures for
mounting the terminal boards.
There are smaller holes on each terminal board that may be
used to secure wiring with tie wraps.
Refer to Figure 2.13 on page 29 for AITB dimensions.
Refer to Figure 2.14 on page 30 for EITB dimensions.
Refer to Figure 2.15 on page 31 for TB50 dimensions.
28
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
For more detailed specification information, refer to Chapter 7,
Specifications.
3.6"
(91 mm)
2.0"
(51 mm)
5.1"
4.70"
(128
(119mm)
mm)
5.756"
5.10"
L
(146mm)
mm)
(130
2.6"
(66 mm)
4.0" W
(102 mm)
Figure 2.13 AITB Dimensions / Clearances
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
2.2 in.
(56 mm)
3.4 in.
(86 mm)
3.8 in. L
(97 mm)
1.6 in.
(41 mm)
2.0 in. W
(51 mm)
Figure 2.14 EITB Dimensions / Clearances
30
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
3.6 in.
(91 mm)
2.3 in.
(58 mm)
3.4 in.
(86 mm)
4.1in. L
(104 mm)
2.6 in.
(66 mm)
4.2 in.W
(102 mm)
Figure 2.15 TB50 Dimensions / Clearances
DIN Rail Mounting
All factory terminal boards snap onto a DIN rail. A TB50 is
shown in the following figures for illustration purposes only.
To install a terminal board on a DIN rail, place the hook side of
the mounting mechanism over one of the DIN rail lips and snap
the board over the other lip.
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Hook side
Figure 2.16 TB50 Mounted on DIN Rail (Front)
DIN Rail Removal
Place a flat blade screw driver through the slot in the board and
hook the blade into the snap latch. Pry the snap latch away
from the DIN rail lip and repeat for the other side. See Figure
2.17.
Removal
catch for
screwdriver
DIN Rail
snap latch
Hook side
Figure 2.17 TB50 Mounted on DIN Rail (Side)
32
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Panel Mounting
NOTE!
When panel mounting terminal boards, remove the
DIN rail brackets before mounting the boards.
Standoff
Figure 2.18 TB50 Panel Mounted
Stand-offs are provided for all terminal boards.
Doc.# 30002-00 Rev 2.3
1.
Remove the DIN rail mounting brackets from terminal
board.
2.
Select a location with enough clearance for the board and
its SCSI cable. Refer to Figure 2.15 on page 31 for installed
clearances.
3.
When a location has been determined for board, mark the
four mounting holes.
4.
Drill and tap the four #6-32 mounting holes.
5.
Place the terminal board so the standoffs are aligned with
the holes. insert the screws in to the standoffs and tighten
them.
Watlow Anafaze
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Mounting an SDAC Module
Follow these steps to install the SDAC module:
1.
Select a location for installation. The SDAC is designed for
wall mounting. It should be installed as close to the
controller as possible.
2.
Mark and drill four holes for screw mounting. Use the diagrams below for the correct locations.
3.
Install the unit with the four #4 screws.
3.60 in.
(91 mm)
Electrical
connections
3.00 in.
(76 mm)
4.68 in.
(119 mm.)
Electrical
connections
1.75 in.
(44 mm)
5.40 in.
(137 mm)
Figure 2.19 SDAC Dimensions
System Wiring
Successful installation and operation of the control system can
depend on placement of the components and on selection of the
proper cables, sensors, and peripheral components.
Routing and shielding of sensor wires and proper grounding of
components can insure a robust control system. This section
includes wiring recommendations, instructions for proper
grounding and noise suppression, and considerations for
avoiding ground loops.
ç
CAUTION!
34
Never route low power circuits next to high power AC
wiring. Instead, physically separate high power
circuits from the controller. If possible, install high
voltage AC power circuits in a separate panel.
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
ç
CAUTION!
Power, input or output circuits with hazardous voltage
levels should not have any live accessible parts.
Wiring Recommendations
Keep the following guidelines in mind when selecting wires and
cables:
•
Use stranded wire. (Solid wire can be used for fixed
service; but it makes intermittent connections when you
move it for maintenance.)
•
Use #20 AWG TC extension wire. Larger or smaller sizes
may be difficult to install, may break easily, or may cause
intermittent connections.
•
Use shielded wire. (The electrical shield protects the
signals and the PPC-2000 from electrical noise.) Connect
only one end of the shield to earth ground.
•
Use copper wire for all connections other than
thermocouple sensor inputs.
See Table 2.9 for cable recommendations.
Table 2.9
Function
Cable Recommendations
Mfr. P/N
No. of
Wires
AWG
Gauge
Analog Inputs
Belden #9154
Belden #8451
2
2
20
22
RTD Inputs
Belden #8772
Belden #9770
3
3
20
22
TC Inputs
TC Ext. Wire
2
20
Digital PID Outputs
and Digital I/O
Belden #9539
Belden #9542
9
20
24
24
Analog Outputs
Belden #9154
Belden #8451
2
2
20
22
Computer
Communication:
RS232, RS422,
RS485, or 20mA
Belden #9729
Belden #9730
Belden #9842
Belden #9843
Belden #9184
4
6
4
6
4
24
24
24
24
22
Max.
Length
4000 ft.
4000 ft.
6000 ft.
Noise Suppression
The PPC-2000’s outputs are designed to drive resistive loads.
Open collector outputs can drive solid state relays. These relays
may in turn operate more inductive types of loads such as
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Watlow Anafaze
35
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
electromechanical relays, alarm horns and motor starters.
Such devices may generate electromagnetic interference (EMI
or noise). If the controller is placed close to sources of EMI, it
may not function correctly. Below are some tips on how to
recognize and avoid problems with EMI.
Symptoms of RFI/EMI
If your controller displays the following symptoms, suspect
EMI:
•
Measured values for analog inputs fluctuate or are
incorrect.
•
Open collector outputs fail.
•
The watchdog time out LED on the Processor Module
lights.
EMI may also damage the digital output circuit—so digital
outputs will not turn on. If the digital output circuit is
damaged, return the controller to Watlow Anafaze for repair.
Avoiding Noise Problems
To avoid RFI/EMI noise problems:
36
•
PPC-2022 32 analog input module must be used with
isolated (ungrounded) thermocouples only.
•
PPC-2022 32 analog input module should not be used with
thermocouples that are embedded within heaters as some
cartridge heaters are constructed.
•
Separate the 120 or 240Vac power leads from the low level
input and output leads connected to the controller. Don't
run the digital I/O or control output leads in bundles with
120Vac wires.
•
Where possible, use solid state relays (SSRs) instead of
electromechanical (EM) relays. If you must use EM relays,
try to avoid mounting them in the same panel as the PPC2000 series equipment.
•
When switching an inductive load such as an
electromechanical relay or solenoid, install a snubber
across the load. Use a 0.01 microfarad capacitor rated at
1000Vac (or higher) in series with a 47 Ohm, 0.5 watt
resistor across the NO contacts of the relay load. See
Chapter 2, Connecting to the Relay Outputs on the PPC206x on page 70 for specific instructions on using snubbers
with the PPC-206x modules.
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
•
You can use other voltage suppression devices, but they
are not usually required. For instance, you can place a
metal oxide varistor (MOV) rated at 130Vac for 120Vac
control circuits across the load, which limits the peak AC
voltage to about 180Vac. You can also place a transorb
(back to back zener diodes) across the digital output,
which limits the digital output voltage.
The above steps will eliminate most EMI/RFI noise problems.
If you have further problems or questions, please contact
Watlow Anafaze.
Avoiding Ground Loops
Ground Loops can cause instrument errors or malfunctions. Do
not connect any of the following pins to each other or to earth
ground:
•
DC power common terminals on the PPC power supply
and PPC-2010 Processor Module
•
DC common terminals on TB50s
•
Analog common terminals on AITBs
•
Signal common terminals on the EITB or other devices
connected to the encoder inputs on a PPC-2030
Watlow Anafaze strongly recommends that you:
•
Isolate outputs through solid state relays, where possible.
•
Isolate RTDs or “bridge” type inputs from ground.
Connecting I/O to the PPC-2010
A TB50 connects to the PPC-2010 Processor module through
the 50 pin SCSI connector. Refer to Figure 2.20 on page 38. The
terminal block interfaces to field wiring of the digital I/O
(sensors, actuators, relays, SSRs, etc.).
Connecting the TB50 to the PPC-2010 Module
Refer to Figure 2.20 on page 38. Connect the SCSI connector
from the PPC-2010 module to the TB50.
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
37
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
TB50
pin 1
50-pin SCSI
Connector
PPC-2010
Bottom View
Figure 2.20 PPC-2010 Connection to TB50
NOTE!
If more than one module in the PPC system is
connected to a terminal board using a 50-pin SCSI
connector, label each end of each cable and each
terminal board with the address of the module to
which it should be connected.
TB50 Connections
Connect digital inputs and digital outputs for control signals,
alarms, and digital field I/O to the TB50. When connected to
the PPC-2010 Processor module, one pulse signal input and up
to five SDAC analog output modules can be connected to the
TB50. Table 2.10 on page 39 shows the TB50 pinout for use
with the PPC-2010.
Use 14 to 22 AWG wire. When making connections, tighten to
0.5 to 0.6 Nm, or 4.5 to 5.4 inch-pound.
38
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Table 2.10
Module I/O Number
Doc.# 30002-00 Rev 2.3
Processor Module I/O Connections
TB-50
Terminal
AnaWin3 Name
(Dig I/O Spreadsheet)1
PPC1:Proc 0.0.1
Digital In/Out 1
Counter 1
Frequency 1
1
PPC1:Proc 0.1.1C2
PPC1: Proc 0.2.1 F
Digital In/Out 2
2
PPC1: Proc 0.0.2
Digital In/Out 3
3
PPC1: Proc 0.0.3
Digital In/Out 4
4
PPC1: Proc 0.0.4
Digital In/Out 5
5
PPC1: Proc 0.0.5
Digital In/Out 6
6
PPC1: Proc 0.0.6
Digital In/Out 7
7
PPC1: Proc 0.0.7
Digital In/Out 8
8
PPC1: Proc 0.0.8
Digital In/Out 9
9
PPC1: Proc 0.0.9
Digital In/Out 10
10
PPC1: Proc 0.0.10
Digital In/Out 11
11
PPC1: Proc 0.0.11
Digital In/Out 12
12
PPC1: Proc 0.0.12
Digital In/Out 13
13
PPC1: Proc 0.0.13
Digital In/Out 14
14
PPC1: Proc 0.0.14
Digital In/Out 15
15
PPC1: Proc 0.0.15
Digital In/Out 16
16
PPC1: Proc 0.0.16
Digital In/Out 17
17
PPC1: Proc 0.0.17
Digital In/Out 18
18
PPC1: Proc 0.0.18
Digital In/Out 19
19
PPC1: Proc 0.0.19
Digital In/Out 20
20
PPC1: Proc 0.0.20
Digital In/Out 21
21
PPC1: Proc 0.0.21
Digital In/Out 22
22
PPC1: Proc 0.0.22
Digital In/Out 23
23
PPC1: Proc 0.0.23
Digital In/Out 24
24
PPC1: Proc 0.0.24
Digital Out 25
25
PPC1: Proc 0.0.25
Digital Out 26
26
PPC1: Proc 0.0.26
Digital Out 27
27
PPC1: Proc 0.0.27
Digital Out 28
28
PPC1: Proc 0.0.28
Digital Out 29
29
PPC1: Proc 0.0.29
Digital Out 30
30
PPC1: Proc 0.0.30
Digital Out 31
31
PPC1: Proc 0.0.31
Digital Out 32
32
PPC1: Proc 0.0.32
Digital Out 33
33
PPC1: Proc 0.0.33
Digital Out 34
34
PPC1: Proc 0.0.34
Watlow Anafaze
39
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Module I/O Number
TB-50
Terminal
AnaWin3 Name
(Dig I/O Spreadsheet)1
Digital Out 35
35
PPC1: Proc 0.0.35
Digital Out 36
36
PPC1: Proc 0.0.36
Digital Out 37
37
PPC1: Proc 0.0.37
Digital Out 38
38
PPC1: Proc 0.0.38
Digital Out 39
39
PPC1: Proc 0.0.39
Digital Out 40
40
PPC1: Proc 0.0.40
Digital Out 41
SDAC Out 41
41
PPC1: Proc 0.0.41
Digital Out 42
SDAC Out 42
42
PPC1: Proc 0.0.42
Digital Out 43
SDAC Out 43
43
PPC1: Proc 0.0.43
Digital Out 44
SDAC Out 44
44
PPC1: Proc 0.0.44
Digital Out 45
SDAC Out 45
45
PPC1: Proc 0.0.45
Digital Out 46
SDAC Clock
46
PPC1: Proc 0.0.46
Global Alarm
47
PPC1: Proc 0.0.47
CPU Watchdog
48
PPC1: Proc 0.0.48
Com (DC Common for
Input Return)
49,50
N/A
1.The name is shown for the first PPC-2000 in the system.
See Digital I/O on page
132 for a complete explanation of digital I/O names.
2. Both count and frequency are measured for the pulse input.
See Inputs on page
127 for an explanation of analog input names.
Connecting Digital Inputs
The PPC-2010 module can accept digital inputs. When the
resistance of an input device is 27 kOhm or greater, the input
is considered off by the PPC-2000. When the resistance is 1
kOhm or less, the input is considered on.
To install a switch as a digital input, connect one lead to the DC
Common input return on the TB50. Connect the other lead to
the desired digital input on the TB50. Refer to Table 2.10 on
page 39 for screw terminal numbering.
Use the Digital I/O parameters to configure digital inputs.
Refer to Digital I/O on page 132.
40
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
{Add examples with transistor inputs on
digital and pulse inputs.}
Chapter 2: Hardware Installation
Digital
Input
Device
TB50
Digital In
Com
Figure 2.21 Wiring Digital Inputs
Connecting Counter or Frequency Inputs
PPC-2010 module accepts a single-phase pulse signal from
devices such as encoders. Counts and frequencies of the inputs
may be scaled with user selectable parameters. See Setting up
User Selectable Linear Inputs on page 98 for more information.
The PPC-2010 module can accommodate encoder signals up to
24Vdc. The following figures illustrate connecting encoders:
TB50
PPC-2010
+5Vdc
10 kOhm
Encoder
Frequency/Counter Input
Com
Figure 2.22 Encoder with 5Vdc TTL Signal
Connecting Digital Outputs
The digital outputs sink current from a load connected to the
controller’s power supply, or another power supply referenced
to the PPC-2000 power common. Do not exceed +24 volts on the
outputs.
If you must tie the external load to ground, or if you cannot
connect it as shown in Figure 2.23 through Figure 2.25, use a
solid state relay to drive your load.
The outputs conduct current when they are LOW or ON. The
maximum current sink capability is 100mA at 24Vdc. They
cannot ‘source’ current to a load.
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
41
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
+ 12-24
-
PS
PPC
2010
TB50
+5
Digital
Out
SSR
Figure 2.23 Powering Output with 5Vdc from PPC
Supply
+
PS
-
PPC
2010
TB50
Digital
Out
SSR
Figure 2.24 Powering Output with 12-24Vdc from
PPC supply
+
PS
for
controller PS
for
Output
-
PPC
2010
TB50
Digital
Out
SSR
Figure 2.25 Powering Output with Separate Power
Supplies
42
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Using the CPU Watchdog Signal
The PPC system constantly monitors the functioning of its
microprocessor. The CPU watchdog output is Low (on) when
the microprocessor is operating; when it stops operating, the
output goes High (off). This sink output is available on screw
terminal #48 on the TB50 attached to the PPC-2010 Processor
module.
The figure below shows the recommended circuit for the CPU
Watchdog signal output.
PPC-IPS-2
+ 5Vdc
CPU
Watchdog
(pin 48)
+
SSR
Monitoring or
Interlocking
Device
-
TB50
Figure 2.26 Recommended circuitry for CPU
Watchdog
SDAC Connections
Up to 5 Serial Digital to Analog Converter (SDAC) modules can
be connected to digital outputs on the processor module. Each
can provide an analog current or voltage signal.
Single SDAC Systems
Use the +5V output on the PPC-IPS-2 to power SDACs. Use
stranded 18 to 22 gauge wire for most installations. Refer to
Figure 2.27 on page 44 for system setup.
Doc.# 30002-00 Rev 2.3
•
Connect SDAC Pin 1 to the +5V terminal on the power
supply.
•
Connect SDAC Pin 2 to the DC COM terminal on the
power supply.
•
If a separate power supply is used, connect the common to
the DC COM on the PPC-2000 power supply.
•
Connect SDAC Pin 3 to the SDAC clock output on the
processor’s TB50 (digital output 46).
•
Connect SDAC pin 4 to the desired control output on the
TB50 (digital output 41-45).
•
Connect SDAC pins 5 and 6 to the input of the controlled
device.
Watlow Anafaze
43
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Multiple SDAC Systems
As many as 5 SDACs can be run from one PPC-2000. Be sure to
provide sufficient current. Use stranded 18 to 22 gauge wire for
most installations. Refer to Figure 2.27 for system setup.
•
Connect SDAC Pin 1 to the +5V terminal on the power
supply.
•
Connect SDAC Pin 2 to the DC COM terminal on the
power supply.
•
If a separate power supply is used, connect the common to
the DC COM on the PPC-2000 power supply.
•
Connect SDAC Pin 3 to the SDAC clock output on the
TB50 (digital output 46).
•
Connect SDAC pin 4 to the desired control output on the
TB50 (digital output 41-45).
•
Connect SDAC pins 5 and 6 to the input of the controlled
device.
Daisy chain up to 5
SDAC
PPC-IPS-1
or other +5V
Power Supply
SDAC
+5V
#1
+5V In
DC COM
#2
COM In
#3
CLK In
#4
Data In
#5
+ Out
#6
- Out
PPC-2010
Processor
DC COM
TB50
SCSI
Connection
SDAC Clock
Control
Output
Electrical
Isolation
46
41 to 45
Load
+
Figure 2.27 Wiring Single/Multiple SDACs
44
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Connecting Analog Inputs to the
PPC-2021 — 2025
The Analog Input Terminal Board (AITB) connects to the
analog input module through the SCSI connector (bottom
center of the analog input module). The AITB accommodates
wiring thermocouples, RTDs, and voltage/current linear
inputs.
AITB
PPC-202X
50-pin SCSI
Connector
Figure 2.28 PPC-2021 — 2025 Connection
to AITB
Connecting the AITB to the PPC-202x
Refer to Figure 2.28. Connect the 50-pin SCSI connector from
the analog input module(s) to the analog input terminal block
(AITB). Table 2.13 on page 48 shows the AITB pinout.
NOTE!
Doc.# 30002-00 Rev 2.3
If more than one AITB has been installed, it may be
useful to label both ends of the SCSI cable and the
AITB with the address selected on the corresponding
analog input or high isolation analog input module.
Watlow Anafaze
45
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Sensor Keys
Sensor keys with built-in jumpers or resistors are used to
customize the AITB for various sensor types. Insert the
appropriate key in the socket provided on the AITB. See Table
2.11 for a description of the various keys. There are two rows of
eight key sockets. Each socket location is labeled IN1 to IN16
which correlate with each Analog In or High Isolation Analog
input address. Keys should be inserted with the component
side facing the terminal blocks. Figure 2.29 illustrates key
installation.
keys
(component
side of keys face
terminal blocks)
Figure 2.29 Inserting Sensor Keys in AITB
Table 2.11
Key
46
Sensor Keys
Color
Used
with
Sensors
TC
None
TC and Voltage
All
RTD
Red
2-Wire or 3-Wire
Platinum 100Ω RTD
2021
2024
2025
Differential
Current
Blue
0-20mA
2021
2024
2025
Single-Ended
Current
Black
0-20mA
2022
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
Chapter 2: Hardware Installation
P1
PPC-2000 User’s Guide
Indicates
component
side
Color indicates
key type
Figure 2.30 An Input Key
AITB Connections
The AITB accommodates wiring thermocouples, RTDs, and
voltage/current linear inputs for all analog input modules.
Table 2.12 describes each analog module and Table 2.13 on
page 48 correlates the AITB labels with the sensor wire
connections for the various modules.
When connecting sensor wires, tighten to 0.5 – 0.6 Nm, or 4.5 –
5.4 inch-pound.
Table 2.12
Module
Doc.# 30002-00 Rev 2.3
Numbers and Types of Inputs by
Module Type
Number
of
Inputs
Differential or
Single-ended
Note
PPC-2021
16
Differential
PPC-2022
32
Single-ended
PPC-2024
8
Differential
High Isolation
PPC-2025
16
Differential
High Isolation
Watlow Anafaze
47
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Table 2.13
Sensor Connections to the AITB
AITB Connection
(Terminal Numbers)
Module
I/O
Number
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
Input 9
Input 10
Input 11
Input12
Input 13
Input 14
Input 15
Input16
Input 17
Input 18
Input 19
Input 20
Input 21
Input 22
Input 23
Input 24
Input 25
Input 26
Input 27
Input 28
Input 29
Input 30
Input 31
Input 32
Differential
PPC-2021
PPC-2024
PPC-2025
Single-Ended
PPC-20222
+
-
+
-
1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
12A
13A
14A
15A
16A
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
1B
2B
3B
4B
5B
6B
7B
8B
9B
10B
11B
12B
13B
14B
15B
16B
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
1A
1B
2A
2B
3A
3B
4A
4B
5A
5B
6A
6B
7A
7B
8A
8B
9A
9B
10A
10B
11A
11B
12A
12B
13A
13B
14A
14B
15A
15B
16A
16B
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
Com
AnaWin3 Name
(Input
Spreadsheet)1
PPC1:AI 1.1
PPC1:AI 1.2
PPC1:AI 1.3
PPC1:AI 1.4
PPC1:AI 1.5
PPC1:AI 1.6
PPC1:AI 1.7
PPC1:AI 1.8
PPC1:AI 1.9
PPC1:AI 1.10
PPC1:AI 1.11
PPC1:AI 1.12
PPC1:AI 1.13
PPC1:AI 1.14
PPC1:AI 1.15
PPC1:AI 1.16
PPC1:AI 1.17
PPC1:AI 1.18
PPC1:AI 1.19
PPC1:AI 1.20
PPC1:AI 1.21
PPC1:AI 1.22
PPC1:AI 1.23
PPC1:AI 1.24
PPC1:AI 1.25
PPC1:AI 1.26
PPC1:AI 1.27
PPC1:AI 1.28
PPC1:AI 1.29
PPC1:AI 1.30
PPC1:AI 1.31
PPC1:AI 1.32
1 The
AnaWin3 name is shown for the first Analog Input module on the first PPC2000 in the system. See Inputs on page 127 for a full explanation of analog input
naming.
2 For the single-ended module the negative sensor lead is connected to any one of
the Com (Analog Common) terminals.
48
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Table 2.14
Power Connections on AITB
Voltage
NOTE!
AITB Terminals
10.00V Ref
Ref (4 PL.)
Analog Common
Com (8 PL.)
The Ref voltage is provided for special sensor types.
Do not use this voltage without consulting Watlow
Anafaze.
Connecting Thermocouples
NOTE!
Connect thermocouple shields directly to a good
frame or chassis ground. Connect thermocouple
shields at one end only, either near the terminal board
or the sensor end.
A thermocouple is connected in a differential configuration by
wiring the positive signal lead to the A terminal of the proper
input and the negative signal lead to the B terminal of the
same input. The designators are located on the terminal block
cards near each screw terminal. See Figure 2.31.
AITB
+
1A (input 1+)
-
frame ground
shield
(if present)
+
-
frame ground
1B (input 1-)
2A (input 2+)
2B (input 2-)
shield
(if present)
Figure 2.31 Thermocouples Connected to
Differential Inputs 1 and 2
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
49
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
A T/C is connected to a single-ended input by wiring the
positive signal lead to the A or B terminal and the negative
signal lead to the analog COM terminal. See Figure 2.32 and
refer to Table 2.13 on page 48.
∫
WARNING!
Thermocouples connected to single-ended inputs
(PPC-2022) must be isolated (ungrounded) and
should not be embedded within heater elements as
some cartridge heaters are constructed.
.
AITB
1A (input 1+)
shield
(if present)
2A (input 2+)
frame ground
Analog COM
shield
(if present)
Figure 2.32 Thermocouples Connected to
Single-ended Inputs 1 and 2
Connecting RTDs
Two-wire RTDs are connected between the A and B terminals
of the selected input. They may only be used with a differential
analog input module. A jumper wire must be added on the
terminal board from the B terminal to the COM terminal. See
Figure 2.33 on page 51.
50
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
AITB
1A (input 1+)
1B (input 1-)
2A (input 2+)
2B (input 2-)
COM
Figure 2.33 Wiring 2-Wire RTDs: Input 1 and 2
Shown
Three-wire RTDs may only be used with differential analog
input modules. The single wire side of a 3-wire RTD sensor
A
terminal, one of the double wire sides
connects to the COM
B terminal and the other connects to the COM
connects to the A
B
terminal. Both A and B terminals must be of the same desired
input, i.e., 1A and 1B. See Figure 2.34.
AITB
1A (input 1+)
1B (input 1-)
2A (input 2+)
2B (input 2-)
COM
Figure 2.34 Wiring 3-Wire RTDs: Input 1 and 2
Shown
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
51
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
ç
CAUTION!
Do not connect the COM terminals on the AITB to
earth ground. Connecting COM to earth ground limits
the input protection to ±10Vac and could result in
damage to the input circuit.
Connecting Sensors with Linear Voltage Signals
For sensors with single output connections, connect the
negative input (B terminal) to the sensor common terminal.
Differential voltage transducers or sensors, such as bridges,
should be connected with the positive signal lead on the A
terminal and the negative signal lead to the B terminal for the
selected input. See Figure 2.35.
Check sensor power supply connections and ground
connections to avoid exceeding the common mode range of the
Analog Input module or creating ground loops.
+
Transducer
with linear
voltage
output
COM
+
Transducer
with linear
voltage
output
AITB
1A (input 1+)
1B (input 1-)
2A (input 2+)
2B (input 2-)
COM
Figure 2.35 Connecting Linear Voltage Signals to
Differential Inputs 1 and 2
Single-ended voltage sources should have the positive lead on
the positive terminal of the desired input. The negative lead
should be connected to the COM terminal. See Figure 2.36 on
page 53.
52
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
AITB
+
Transducer
with linear
voltage
output
1A (input 1+)
-
+
Transducer
with linear
voltage
output
2A (input 2+)
A COM
Figure 2.36 Connecting Linear Voltage Signals to
Single-ended Inputs 1 and 2
Connecting Sensors with Linear Current Signals
Differential current transducers or sensors should be
connected with the positive signal lead on the A terminal and
the negative signal lead to the B terminal for the selected
input. See Figure 2.37.
10 V Max
+ power
28V Max
Power
Supply
+
–
Typical
2-wire
current
transmitter
I
+ power
28V Max
3A(Input 3+) + power
Typical
Typical
I
out
3-wire
3-wire
current
current
source
3B(Input 3-) sinking
transmitter
transmitter
–
– power
I
1A(Input 1+)
1B(Input 1-)
2A(Input 2+)
2B(Input 2-)
Analog Com (optional)
Figure 2.37 Connecting Current Inputs to a
Differential Input Module:
Input 1, 2, and 3 Shown
Single-ended current sources should be have the positive lead
on the positive terminal of the desired input. The negative lead
should be connected to the COM terminal. See Figure 2.38 on
page 54.
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
53
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
{Redraw like other I/O diagrams.}
+ power
28V Max
Power
Supply
+
–
Typical
2-wire
current
transmitter
I
+ power
28 V Max
Typical
3-wire
current
source
transmitter
–
–
1A(Input 1+)
Com
I
2A(Input 2+)
Com
Figure 2.38 Connecting Current Inputs to a
Single-ended Analog Input
Module: Input 1 and 2 Shown
54
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Connecting Encoders and Analog Outputs to
the PPC-2030
The PPC-2030 accepts four encoder inputs and outputs four
current or voltage signals. Encoder signals are connected to the
module via two HD-15 cables. These cables may be used in
conjunction with up to two EITBs or may be connected directly
from the encoders to the module.
Connect analog outputs via the analog output terminal block as
shown in Figure 2.39.
J4
J4 Encoder
Input
connector
inputs 3 & 4
(HD-15 female)
J3
J3 Encoder
Input
connectors
inputs 1 & 2
(HD-15 female)
J2
44+
33+
J1
22+
11+
J2 Analog
Output Terminal
Block
outputs 3 & 4
J1 Analog
Output Terminal
Block
outputs 1 & 2
Figure 2.39 PPC-2030 Connections (Bottom View)
Connecting the Encoder Input Cable to the PPC-2030
Connect the 15-pin, HD cable(s) between J1 or J2 on the PPC2030 shown in Figure 2.39 and the encoder input terminal
block (EITB).
Figure 2.40 on page 56 illustrates the EITB. Table 2.15 on page
56 shows the EITB pinout and Table 2.18 on page 59 shows the
HD D-type connector pinout. Analog Output Connections on
page 60 discusses analog outputs from the PPC-2030.
NOTE!
Doc.# 30002-00 Rev 2.3
If more than one EITB has been installed, it may be
useful to label both ends of the HD-15 connector and
each EITB with the corresponding module address
and jack number.
Watlow Anafaze
55
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
EITB Connections
Table 2.15 and Table 2.16 indicate the encoder connections to
the EITB connected to the Encoder In Analog Out module.
Table 2.17 on page 57 lists the terminals that carry power.
pin 1
J2
pin 12
Figure 2.40 PPC-EITB-1
Table 2.15
Module
I/O Number
Count 1
Frequency 1
Count 2
Frequency 2
Table 2.16
Module
I/O Number
Count 3
Frequency 3
Count 4
Frequency 4
Encoder Connections to the EITB
Connected to J3 on the PPC-2030
EITB Terminal
Phase 1 Phase 2
+
+
2
3
4
5
8
9
10
11
AnaWin3 Name
(Input
Spreadsheet)1
PPC1:EIAO 11.1.1 C
PPC1:EIAO 11.2.1 F
PPC1:EIAO 11.1.2 C
PPC1:EIAO 11.2.2 F
Encoder Connections to the EITB
Connected to J4 on the PPC-2030
EITB Terminal
Phase 1 Phase 2
+
+
2
3
4
5
8
9
10
11
AnaWin3 Name
(Input
Spreadsheet)1
PPC1:EIAO 11.1.3 C
PPC1:EIAO 11.2.3 F
PPC1:EIAO 11.1.4 C
PPC1:EIAO 11.2.4 F
1.The AnaWin3 name is shown for the Encoder In Analog Out module with address
11 on the first PPC-2000 in the system. See Inputs on page 127 for a full
explanation of Analog input naming. Both count and frequency are measured for
each input.
56
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 2: Hardware Installation
Table 2.17
Power Connections on EITB
Voltage
EITB Terminals
+5Vdc
1, 7
COM
6, 12
Encoder Wiring
The EITB accommodates four configurations of frequency/
counter inputs:
•
Single-ended/single phase
•
Single-ended/quadrature
•
Differential/single phase
•
Differential/quadrature
Note that these are four unique inputs and each input has two
phases. Both phases are used only in quadrature mode
nominally.
EITB
+
2 (input 1 phase 1+)
S1
+
8 (input 2 phase 1+)
S2
-
12 (COM)
Figure 2.41 EITB Single-ended Single Phase
Connections: Input 1 and 2 Shown
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
57
Chapter 2: Hardware Installation
PPC-2000 User’s Guide
1+
Q1
2+
EITB
2 (input 1 phase 1+)
4 (input 1 phase 2+)
COM
1+
8 (input 2 phase 1+)
2+
10 (input 2 phase 2+)
Q2
COM
12 (COM)
Figure 2.42 EITB Single-ended Quadrature
Connections: Input 1 and 2 Shown
EITB
S1
+
2 (input 1 phase 1+)
-
3 (input 1 phase 1-)
12 (COM)
+
S2
-
8 (input 2 phase 1+)
9 (input 2 phase 1-)
12 (COM)
Figure 2.43 EITB Differential Single Phase
Connections: Input 1 and 2 Shown
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Chapter 2: Hardware Installation
EITB
2 (input 1 phase 1+)
1+
3 (input 1 phase 1-)
1Q1
2+
4 (input 1 phase 2+)
2-
5 (input 1 phase 2-)
12 (COM)
1+
8 (input 2 phase 1+)
1-
9 (input 2 phase 1-)
2+
10 (input 2 phase 2+)
2-
11 (input 2 phase 2-)
Q2
12 (COM)
Figure 2.44 EITB Differential Quadrature
Connections: Input 1 and 2 Shown
Encoder Connections without the EITB
Encoders may be connected directly to the PPC-2030 module.
Table 2.17 and Table 2.19 on page 60 indicate the functional
pinout for HD-15 connectors connected to the Encoder In
Analog Out module connectors J1 and J2.
Table 2.18
Module
I/O
Number
Count 1
Frequency 1
Count 2
Frequency 2
Count 3
Frequency 3
Count 4
Frequency 4
HD-15 Encoder Signal Connections
Connector and Pin
Number
Phase 1
Phase 2
+
-
+
-
J3-1
J3-2
J3-3
J3-10
J3-6
J3-7
J3-8
J3-11
J4-1
J4-2
J4-3
J4-10
J4-6
J4-7
J4-8
J4-11
AnaWin3 Name
(Input Spreadsheet)1
PPC1:EIAO 11.1.1 C
PPC1:EIAO 11.2.1 F
PPC1:EIAO 11.1.2 C
PPC1:EIAO 11.2.2 F
PPC1:EIAO 11.1.3 C
PPC1:EIAO 11.2.3 F
PPC1:EIAO 11.1.4 C
PPC1:EIAO 11.2.4 F
1 The AnaWin3 name is shown for the Encoder In Analog Out module with address
11 on the first PPC-2000 in the system. Refer to Inputs on page 127 for a full
explanation of analog input naming. Both count and frequency are measured for
each input.
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Table 2.19
HD-15 Power Connections
Voltage
Pin Number
+5Vdc
12, 15
COM
13, 14
Analog Output Connections
The connector pinouts are shown in Table 2.20. Use 16-28 AWG
wire. When making connections, tighten to 0.5 to 0.6 Nm, or 4.5
to 5.4 inch-pound.
J2
44+
33+
J1
22+
11+
Outputs 3 & 4
Outputs 1 & 2
DIN Rail Latch
Figure 2.45 PPC-2030 Analog Out Terminal Block
Table 2.20
Analog Output Connections on
Encoder In Analog Out Module
Module I/O
Number
Encoder In Analog
Out Module
Connections
Analog Out 1
Analog Out 2
Analog Out 3
Analog Out 4
+
-
J1-1+
J1-2+
J2-3+
J2-4+
J1-1J1-2J2-3J2-4-
AnaWin3 Name
(Input Spreadsheet)1
PPC1:EIAO 11.3.1
PPC1:EIAO 11.3.2
PPC1:EIAO 11.3.3
PPC1:EIAO 11.3.4
1 The AnaWin3 name is shown for the Encoder In Analog Out module with address
11 on the first PPC-2000 in the system. Refer to Outputs on page 135 for a full
explanation of Analog output naming.
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Chapter 2: Hardware Installation
P PC-2030
1+
+
+
4-20mAdc
-
I
1-
Load
-
2+
+
+
0-10Vdc
-
Load
2-
-
Figure 2.46 Analog Output Connections on a
PPC-2030: Outputs 1 and 2 Shown
Connecting I/O to the PPC-2040
A TB50 connects to a PPC-2040 Digital I/O module through the
50 pin SCSI connector. Refer to Figure 2.47 on page 62. The
terminal block interfaces to field wiring of the digital I/O
(sensors, actuators, relays, SSRs, etc.).
Connecting the TB50 to the PPC-2040 Module
Refer to Figure 2.47 on page 62. Connect the SCSI connector
from the PPC-2040 module to the TB50.
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
TB50
pin 1
50-pin SCSI
Connector
PPC-2040
Bottom View
Figure 2.47 PPC-2040 Connection to TB50
NOTE!
To avoid confusing the SCSI cables during servicing,
label each end of each cable and each terminal board
with the address of the module to which it should be
connected.
TB50 Connections
Connect digital inputs and digital outputs for control signals,
alarms, and digital field I/O to the TB50. The PPC-2040 Digital
I/O Module supports up to 32 digital inputs and outputs and up
to two single-ended counter/frequency inputs. Counter inputs
may be single-phase or quadrature. Connecting one singlephase counter or frequency signal uses one digital input.
Connecting one quadrature input requires two digital inputs.
Table 2.21 on page 63 shows the TB50 pinout when used with
the PPC-2040.
Use 14 to 22 AWG wire. When making connections, tighten to
0.5 to 0.6 Nm, or 4.5 to 5.4 inch-pound.
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Chapter 2: Hardware Installation
Table 2.21
Module I/O Number
Digital In/Out 1
Counter 1 Phase 1
Frequency 1
Digital In/Out 2
Counter 1 Phase 2
Digital In/Out 3
Counter 2 Phase 1
Frequency 2
Digital In/Out 4
Counter 2 Phase 2
Digital In/Out 5
Digital In/Out 6
Digital In/Out 7
Digital In/Out 8
Digital In/Out 9
Digital In/Out 10
Digital In/Out 11
Digital In/Out 12
Digital In/Out 13
Digital In/Out 14
Digital In/Out 15
Digital In/Out 16
Digital In/Out 17
Digital In/Out 18
Digital In/Out 19
Digital In/Out 20
Digital In/Out 21
Digital In/Out 22
Digital In/Out 23
Digital In/Out 24
Digital In/Out 25
Digital In/Out 26
Digital In/Out 27
Digital In/Out 28
Digital In/Out 29
Digital In/Out 30
Digital In/Out 31
Digital In/Out 32
Com (DC Common for
Input Return)
Digital I/O Module Connections
AnaWin3 Name
(Dig I/O Spreadsheet)1
TB-50
Terminal
PPC1:DIO 21.0.1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
37 to 50
PPC1:DIO 21.1.1 C2
PPC1:DIO 21.2.1 F
PPC1:DIO 21.0.2
PPC1:DIO 21.1.1 C
PPC1:DIO 21.0.3
PPC1:DIO21.1.2 C
PPC1:DIO21.2.2 F
PPC1:DIO 21.0.4
PPC1:DIO21.1.2 C
PPC1:DIO 21.0.5
PPC1:DIO 21.0.6
PPC1:DIO 21.0.7
PPC1:DIO 21.0.8
PPC1:DIO 21.0.9
PPC1:DIO 21.0.10
PPC1:DIO 21.0.11
PPC1:DIO 21.0.12
PPC1:DIO 21.0.13
PPC1:DIO 21.0.14
PPC1:DIO 21.0.15
PPC1:DIO 21.0.16
PPC1:DIO 21.0.17
PPC1:DIO 21.0.18
PPC1:DIO 21.0.19
PPC1:DIO 21.0.20
PPC1:DIO 21.0.21
PPC1:DIO 21.0.22
PPC1:DIO 21.0.23
PPC1:DIO 21.0.24
PPC1:DIO 21.0.25
PPC1:DIO 21.0.26
PPC1:DIO 21.0.27
PPC1:DIO 21.0.28
PPC1:DIO 21.0.29
PPC1:DIO 21.0.30
PPC1:DIO 21.0.31
PPC1:DIO 21.0.32
N/A
1.The
AnaWin3 name is shown for the first Digital I/O module on the PPC-2000
system. See Digital I/O on page 132 for a complete explanation of digital I/O
names.
2. Both count and frequency are measured for the pulse input.
See Inputs on page
127 for an explanation of analog input names.
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Connecting Digital Inputs
The PPC-2040 module can accept digital inputs. When the
resistance of an input device is 27 kOhm or greater, the input
is considered off by the PPC-2000. When the resistance is 1
kOhm or less, the input is considered on.
To install a switch as a digital input, connect one lead to the DC
Common input return on the TB50. Connect the other lead to
the desired digital input on the TB50. Refer to Table 2.21 on
page 63 for screw terminal numbering.
Use the Digital I/O parameters to configure digital inputs.
Refer to Digital I/O on page 132.
Digital
Input
Device
TB50
Digital In
Com
Figure 2.48 Wiring Digital Inputs
Connecting Counter or Frequency Inputs
A PPC-2040 module accepts single-phase or quadrature pulse
signals from devices such as encoders. Counts and frequencies
of the inputs may be scaled with user selectable parameters.
See Setting up User Selectable Linear Inputs on page 98 for
more information.
The PPC-2040 module can accommodate encoder signals up to
24Vdc. The following figures illustrate connecting encoders:
TB50
+
1 (input 1 phase 1+)
S1
+
3 (input 2 phase 1+)
S2
-
37 (COM)
Figure 2.49 Single Phase Connections: Input 1
and 2 Shown
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Chapter 2: Hardware Installation
TB50
1 (input 1 phase 1+)
1+
Q1
2 (input 1 phase 2+)
2+
COM
3 (input 2 phase 1+)
1+
4 (input 2 phase 2+)
2+
Q2
COM
37 (COM)
Figure 2.50 Quadrature Connections:
Inputs 1 and 2 Shown.
Connecting Digital Outputs
The digital outputs sink current from a load connected to the
controller’s power supply, or another power supply referenced
to the PPC-2000 power common. Do not exceed +24 volts.
If you must tie the external load to ground, or if you cannot
connect it as shown in Figure 2.51 through Figure 2.53, use a
solid state relay to drive your load.
The outputs conduct current when they are LOW or ON. The
maximum current sink capability is 150mA at 24Vdc. They
cannot ‘source’ current to a load.
PS
+ 12-24
-
PPC
+5
Digital
Out
TB50
SSR
Figure 2.51 Powering Output with 5Vdc from
PPC Supply
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
+
PS
PPC
-
Digital
Out
TB50
SSR
Figure 2.52 Powering Output with 12-24Vdc from
PPC supply
+
PS
for
controller PS
for
Output
PPC
Digital
Out
TB50
+5 to 24Vdc
SSR
Figure 2.53 Powering Output with Separate Power
Supplies
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Chapter 2: Hardware Installation
Connecting Analog Outputs to the PPC-205x
Connect wires directly to the terminals on the bottom of the
PPC-205x modules. The PPC-2050 can source up to eight
analog signals and the PPC-2051 up to four.
Table 2.22 lists the terminal connections for the PPC-2050
module.
16-pin Terminal Block
for Analog Outputs
PPC-2050
PPC-2051
Figure 2.54 PPC-205x Connections (Bottom View)
Table 2.22
Module I/O
Number
Analog Out 1
Analog Out 2
Analog Out 3
Analog Out 4
Analog Out 5
Analog Out 6
Analog Out 7
Analog Out 8
Analog Output Connections on
Analog Out Module
Analog Out Module
Connections
Voltage
AnaWin3 Name
(Input
Spreadsheet)1
Current
+
-
Source
Sink
1A
2A
3A
4A
5A
6A
7A
8A
1B
2B
3B
4B
5B
6B
7B
8B
1B
2B
3B
4B
5B
6B
7B
8B
1A
2A
3A
4A
5A
6A
7A
8A
PPC1:AO 31.1
PPC1:AO 31.2
PPC1:AO 31.3
PPC1:AO 31.4
PPC1:AO 31.5
PPC1:AO 31.6
PPC1:AO 31.7
PPC1:AO 31.8
1.The AnaWin3 name is shown for the Encoder In Analog Out module with address
11 on the first PPC-2000 in the system. Refer to Outputs on page 135 for a full
explanation of Analog output naming.
Doc.# 30002-00 Rev 2.3
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67
Chapter 2: Hardware Installation
NOTE!
PPC-2000 User’s Guide
On the PPC-2050, each consecutive pair of analog
outputs—1-2, 3-4, 5-6 and 7-8—shares an internal
power supply. In current mode the power supply + is
shared, and in voltage mode the common is shared. If
an external power supply is tied into the internal
power supply though the B pin, the signal to each
output may be distorted. It may be necessary to use a
separate external power supply for each analog
output within the pair. Each output on the PPC-2051
has a separate internal power supply so the same
external power supply may be used.
PPC-2050
1A
Sink
-
i
I
Load
+
Source
1B
2A
Sink
I
i
2B
Load
+
Source
+15V
Figure 2.55 Analog Output Connections on a
PPC-2050 Configured for Current:
Outputs 1 and 2 Shown
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Chapter 2: Hardware Installation
PPC-2050
1A
+
v
+
-
Load
-
1B
2A
+
v
+
-
Load
-
2B
com
Figure 2.56 Analog Output Connections on a
PPC-2050 Configured for Voltage:
Outputs 1 and 2 shown
PPC-2051
1A
Sink
-
i
I
1B
Load
+
Source
2A
+
v
+
Load
2B
-
Figure 2.57 Analog Output Connections on a
PPC-2051 Configured for Current and
Voltage: Outputs 1 and 2 shown
NOTE!
Doc.# 30002-00 Rev 2.3
The B terminal sources current and the A terminal
sinks it on outputs configured for current. On outputs
configured for voltage the A terminal is at the greater
potential.
Watlow Anafaze
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Connecting to the Relay Outputs on the
PPC-206x
The PPC-2061 and PPC-2062 provide connections located on
the bottom panel for eight electromechanical relay outputs and
three counter inputs. Relay output field wiring is terminated at
a sixteen position removable terminal block.
16-pin terminal block
for relay outputs
Common Terminals
PPC-2062
PPC-2061
Figure 2.58 PPC-206x Connections
(bottom view)
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Chapter 2: Hardware Installation
Wiring PPC-2061 Relay Outputs
The PPC-2061 has 16 normally open relay outputs. Outputs 1
to 8 share one common, and outputs 9-16 share the second
common. Either AC or DC may be switched. See Figure 2.59
for an example of how to connect to the relay outputs.
Table 2.23 on page 72 lists the connections to the PPC-2060 and
PPC-2061 modules.
PPC-2061
Neutral or 120V
1
Load
Relay 1
Relay 2
2
L2 (AC)
Load
AC or DC
Source
C1
9
L1 (AC)
Neutral or 120V
Load
Relay 9
Relay 10
10
Load
L2 (AC)
AC or DC
Source
C2
L1 (AC)
Figure 2.59 Relay Output Connections on a PPC2061: Outputs 1, 2, 9 and 10 shown
∫
WARNING!
Do not switch AC neutral (L2). Load switching must
occur on the hot (L1) side of the AC line. Failure to do
so could cause injury or death.
Wiring PPC-2062 Relay Outputs
The PPC-2062 has eight normally open, single-contact relay
outputs. The load may be connected to either contact. DC or AC
power may be switched. See Figure 2.60 on page 72 for an
example of how to connect to the relay outputs.
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
PPC-2062
1A
Load
L2 (AC)
Relay 1
AC or DC
Source
1B
2A
L1 (AC)
Load
Relay 2
L2 (AC)
AC or DC
Source
2B
L1 (AC)
Figure 2.60 Relay Output Connections on a
PPC-2062: Outputs 1 and 2 Shown
Table 2.23
Module
I/O Number
Digital Out 1
Digital Out 2
Digital Out 3
Digital Out 4
Digital Out 5
Digital Out 6
Digital Out 7
Digital Out 8
Digital Out 9
Digital Out 10
Digital Out 11
Digital Out 12
Digital Out 13
Digital Out 14
Digital Out 15
Digital Out 16
Relay Output Connections on
PPC-206x Digital Output Modules
Digital Out Module
Connections
PPC-2061
Out
Com
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
C1
C1
C1
C1
C1
C1
C1
C1
C2
C2
C2
C2
C2
C2
C2
C2
PPC-2062
AnaWin3 Name
(Dig I/O Spreadsheet)1
1A
2A
3A
4A
5A
6A
7A
8A
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
PPC1:DO 41.1
PPC1:DO 41.2
PPC1:DO 41.3
PPC1:DO 41.4
PPC1:DO 41.5
PPC1:DO 41.6
PPC1:DO 41.7
PPC1:DO 41.8
PPC1:DO 41.9
PPC1:DO 41.10
PPC1:DO 41.11
PPC1:DO 41.12
PPC1:DO 41.13
PPC1:DO 41.14
PPC1:DO 41.15
PPC1:DO 41.16
1B
2B
3B
4B
5B
6B
7B
8B
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
1 The
AnaWin3 name is shown for the Digital Out module with address 41 on the
first PPC-2000 in the system. See Digital I/O on page 132 for a full explanation
of Digital I/O naming.
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Chapter 2: Hardware Installation
Using Snubbers for Relay Outputs
Relay contacts can arc and/or generate EMI. Over time, arcing
will shorten the life of relay contacts and EMI can disrupt
system functions. Use snubbers—a resistor and capacitor in
series— to protect against EMI and lengthen relay life.
The capacitor should be non-polarized and may be metallized
polyester film or metallized polypropylene and the voltage
rating must be 600Vdc/250Vac. The resistor may be carbon
composition or carbon film. It should be 0.5 or 1 watt with 5%
tolerance. Use 1 watt if the contacts are used in a rapid cycling
application.
The following values are acceptable for most applications using
the PPC-2061 and PPC-2062 relay output modules:
•
Resistor: 120 Ω
•
Capacitor: 0.47 µF
Install the snubber across the contacts or the load. Generally,
it performs more reliably across the contacts.
120/240Vac
H
C
R
Preferred Method
N
Load
Contacts
Alternative Method
Figure 2.61 Snubber Connections
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
Connecting Digital Inputs to the PPC-207x
Connect wires directly to the terminals on the bottom of the
PPC-207x modules. Up to 16 inputs are accommodated.
Depending on the module type, DC and AC inputs are
accommodated.
Input
Connections
Common
Connections
PPC-2070
PPC-2072
PPC-2071
PPC-2073
Figure 2.62 PPC-207x Connections
(bottom view)
Input Device
(2072 only)
-----
PPC-2070/
PPC-2071
1
Input Device
--- --- +
DC
DC
Source Source
+
-----
2
Å
C
Figure 2.63 Input Connections to a PPC-2070 or
PPC-2072: Inputs 1 and 2 shown
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Chapter 2: Hardware Installation
Input Device
(PPC-2073 only)
-----
PPC-2071/
PPC-2073
1
Input Device
2
----- +
DC
DC
Source Source
+ --- --Input Device
Å
C1
Input Device
(PPC-2073 only)
-----
9
Input Device
----+
DC
DC
Source Source
+
10
Å
C2
---
---
Figure 2.64 Input Connections to a PPC-2071 or
PPC-2073: Inputs 1,2, 9 and 10 Shown
PPC-2072/
PPC-2073
C/C1
V+
+
DC
Source
-
Sensor’s
Output 1
Sensor
Circuit
VCurrent Sinking Field Device
Figure 2.65 Connecting a Current Sinking Field
Device to a PPC-2072 or PPC-2073:
Input 1 Shown
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Chapter 2: Hardware Installation
PPC-2000 User’s Guide
PPC-2072/
PPC-2073
C/C1
V–
DC
Source
+
Sensor’s
Output 1
Sensor
Circuit
V+
Current Sourcing Field Device
Figure 2.66 Connecting a Current Sourcing Field
Device to a PPC-2072 or PPC-2073:
Input 1 Shown
Table 2.24
Module I/O
Number
Digital In 1
Digital In 2
Digital In 3
Digital In 4
Digital In 5
Digital In 6
Digital In 7
Digital In 8
Digital In 9
Digital In 10
Digital In 11
Digital In 12
Digital In 13
Digital In 14
Digital In 15
Digital In 16
Digital Input Connections on
PPC-207x Modules
Digital In Module
Connections
PPC-2070
PPC-2072
Input Com
1
2
3
4
5
6
7
8
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
C
C
C
C
C
C
C
C
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
PPC-2071
PPC-2073
Input Com
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
C1
C1
C1
C1
C1
C1
C1
C1
C2
C2
C2
C2
C2
C2
C2
C2
AnaWin3
Name (Dig I/O
Spreadsheet)1
PPC1:DI 51.1
PPC1:DI 51.2
PPC1:DI 51.3
PPC1:DI 51.4
PPC1:DI 51.5
PPC1:DI 51.6
PPC1:DI 51.7
PPC1:DI 51.8
PPC1:DI 51.9
PPC1:DI 51.10
PPC1:DI 51.11
PPC1:DI 51.12
PPC1:DI 51.13
PPC1:DI 51.14
PPC1:DI 51.15
PPC1:DI 51.16
1 The AnaWin3 name is shown for the Digital In module with address 51 on the first
PPC-2000 in the system. See Digital I/O on page 132 for a full explanation of
digital I/O output naming.
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Chapter 2: Hardware Installation
Connecting Power
PPC-IPS-2 Power Supply
The PPC-IPS-2 accepts two ranges of voltages. Connections are
made at screw terminals.
Table 2.25
PPC-IPS-2 Voltage Input Switch
Settings
IPS-2 Switch
Setting
Input Voltage
Range
115V
88-132Vac
230V
176-264Vac
Input
Frequency
47-440Hz
ç
CAUTION!
The PPC-IPS-2 accepts two ranges of voltage. Be sure
to set the switch to the appropriate range before
applying power.
Processor Module
The processor module accepts 10 to 28Vdc. Connect the
terminal labeled +V on the PPC-2010 to the DC power and the
terminal labeled C to the DC common. See Table 2.26 for
connections for the two power supplies.
Table 2.26
Power Supply Connections
PPC-2010
IPS-2
+V
V2
C
COM
Figure 2.67 on page 78 illustrates the connections when using
the PPC-IPS-2.
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V1 +5 Vdc
V1 +5 Vdc
V2 +24 Vdc
+24 Vdc
DC Com
Figure 2.67 PPC-IPS-2 Power Connections
Connecting Communication Ports
Communications ports 1 and 2 on the PPC-2010 Processor
module may be used to communicate with an operator interface
terminal, a computer running AnaWin3, LogicPro, or thirdparty software, or any device capable of acting as a host using
the Modbus RTU protocol.
PPC controllers always act as servers or slaves. The computer
or other host device must act as the client or master.
Communication Ports
Both communication ports support RS-232 and RS-485 signals.
A 4-position, 4-conductor telephone handset connector is
provided for RS-232 communications and an RJ12 connector is
provided for RS-485 communications. Only one of these
connectors may be used. Both ports are optically isolated.
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Communication Cables
Watlow Anafaze supplies flat, oval cables with modular plug
and DB-9 connectors for RS-232. RS-485 cables have RJ12
connectors and bare-wire ends. These cables may be used for
short runs between a PPC and a host device or between a PPC
and a terminal strip or other wiring interface. When using
other cables or connecting over longer distances, select cables
and connectors that meet the standards described in this
section.
Do not use cables from sources other than Watlow Anafaze
unless the shield wire is in the proper position (pin 6) in the
connector. Table 2.27 and Table 2.28 on page 80 describe the
pin outs for the two connector types.
Cable Connector Pin Outs
Cable connectors must have the correct pin outs.
Refer to Figure 2.68 on page 79 to determine the location of pin
1 in the connectors. Refer to Table 2.27 on page 79 for RS-232
cable pin outs. Refer to Table 2.28 on page 80 for the RS-485 pin
out and connections. The colors in the table are for Watlow
Anafaze cables.
pin 1
RS-232: Modular Plug
4-Position, 4-Conductor
Handset Plug
pin 1
RS-485: RJ12
6-Position, 6-Conductor
Plug
Figure 2.68 RS-232 and RS-485 RJ-Type
Connectors
Table 2.27
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RS-232 Connector Pin Outs
Plug
Pin #
Wire Color
PPC
Function
DB9
Pin #
DB25
Pin #
1
Black
Common
5
7
2
Red
R
3
2
3
Green
T
2
3
4
Bare (Shield)
Frame
Ground
N/C
N/C
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Table 2.28
RS-485 Connector Pin Out and
Connections
RJ12
Pin #
Wire Color
PPC
Function
Converter
Connection
1
White or Blue
Common
Common
2
Black
RB
TXB/TDB/TX+
3
Red
TB
RXB/RDB/RX+
4
Green
TA
RXA/RDA/RX-
5
Yellow
RA
TXA/TDA/TX-
6
Bare (Shield)
not used
N/C
Jumpers in RS-232 Connectors
Some software programs and some operator interface
terminals require a Clear to Send (CTS) signal in response to
their Request to Send (RTS) signal, or a Data Set Ready (DSR)
in response to their Data Terminal Ready (DTR). The PPC2000 is not configured to receive or transmit these signals. To
use such software with the PPC, jumper RTS to CTS and DTR
to DSR in the DB connector. Table 2.29 lists the standard pin
assignments for DB-9 and DB-25 connectors.
Table 2.29
RTS/CTS Pins in DB-9 and DB-25
Connectors
DB-9
DB-25
RTS
7
4
CTS
8
5
DTR
4
20
DSR
6
6
Cables manufactured by Watlow Anafaze for RS-232
communications include these jumpers. AnaWin3 and LogicPro
do not require these jumpers and are not affected by their
presence.
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Chapter 2: Hardware Installation
Connecting RS-232 Communications
RS-232 may be used for communications between one PPC and
a host device over cables of up to 50 feet in length.
RS-232 does not support more than two devices on a network.
See Figure 2.69. RS-232 may be used to connect a computer,
through a 232/485 converter, to an RS-485 communications
network with up to 32 PPC controllers. See Figure 2.70.
RS-232 4-pin RJ-type
Serial Port
DB-9 or DB-25
RS-232 Cable
Figure 2.69 Connecting One PPC to a
Computer Using RS-232
Connecting RS-485 Communications
An RS-485 communications network can connect up to 32 PPCs
directly with a host device equipped with an RS-485 port or via
a converter to a host’s RS-232 port. See Figure 2.70. RS-485
wiring can be used over much greater distances than RS-232.
485 Communications
232 Communications
shielded twisted pair cable
serial port
external
resistor
termination
485
terminal
block
optically
isolating
232 to 485
converter
no more
than 10 ft.
flat cable
with RJs
PPC 1
PPC 2
PPC N
Figure 2.70 Connecting Multiple PPCs to a
Computer Using RS-485
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The host computer uses one twisted pair to send messages to
any PPC on the network. All the PPCs receive all the messages.
The one PPC addressed by a particular message uses the other
twisted pair to respond. This twisted pair is shared by the
transmitters of all the PPCs on the network. Only one PPC
transmits at a time.
Therefore, one twisted pair connects the transmitter terminals
at the host computer or converter to the receivers on each of the
controllers. The second twisted pair connects the computer or
converter’s receiver to the transmitters on all the PPCs on the
network. Figure 2.71 illustrates this.
Network wiring should approximate a daisy chain as closely as
possible. Keep the distance from the point at which the wires
are split to the PPC as short as possible. Long spurs can cause
destructive interference of the signals.
Converter or Host
Color (RJ Pin)
PPC 1
RA-
RABlack (2)
Black (2)
RB+
RB+
TA-
TARed (3)
Red (3)
RXB/RDB/RX+
TB+
TB+
White/Blue (1)
DC Common
External
Termination
Resistor
Green (4)
Green (4)
RXA/RDA/RX-
PPC N
Yellow (5)
Yellow (5)
TXA/TDA/TXTXB/TDB/TX+
Color (RJ Pin)
Signal
Common
White/Blue (1)
Not Used
Signal
Common
Not Used
Figure 2.71 RS-485 Wiring
485 Terminal Block
The 485 terminal block accepts an RJ12 cable connector and
converts each line on the cable to a screw terminal. Use the 485
terminal block to wire multiple PPC-2000 controllers together
on the same 485 network. Pins on the terminal block are
designated 1 to 6. The function and number of each pin
corresponds to the function and pin numbers of the 485 ports
on the PPC-2010 module.
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Table 2.30
485 Terminal Block Pin Assignment
485 Terminal
Block Pin
Number
PPC-2010 485
Port Pin Number
Function
1
1
Common
2
2
RB +
3
3
TB +
4
4
TA -
5
5
RA -
6
6
Not used
S
Not used
Not used
Cable Recommendations
Watlow Anafaze recommends Belden #9843 or its equivalent.
This cable includes three, 24 AWG, shielded, twisted pairs. It
should carry signals of up to 19.2 kbaud with no more than
acceptable losses for up to 4000 feet.
RS-485 Network Connections
Run twisted pair from the host or converter to a 485 terminal
block as close to first PPC as possible, and from that point to
another 485 terminal block near the next PPC, and so on.
Connect 485 terminal blocks in series using appropriate
lengths of 485 cable. Be sure to connect all five conductors at
each junction such that the 485 terminal block at each PPC will
see the same signals on each of its pins.
Install the 485 terminal blocks as close to each PPC as possible.
To avoid unacceptable interference, use less than ten cable feet
from the terminal to the PPC serial port.
Use cables with RJ12 plugs to connect from the 485 terminal
blocks to the serial ports on each PPC-2010, or use cables with
bare wires on one end and RJ12 connectors on the other to
connect from terminal strips to the PPCs.
Two Wire RS-485 Connections
By placing jumpers between the (+) pins and between the (-)
pins on the 485 terminal blocks, RS-485 systems may be
configured for two wire connections as well. Use the same
cables with RJ12 plugs as you would use for four wire
connections to connect from the 485 terminal blocks to the
serial ports on each PPC-2010. Connect the two wire RS-485
network to the 485 terminal block according to Figure 2.72.
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Converter or Host
PPC-2000 User’s Guide
Color (RJ Pin)
PPC 1
Yellow (5)
Black (2)
Green (4)
RXB/RDB/RX+
RA-
Black (2)
RB+
RB+
Green (4)
RXA/RDA/RX-
TARed (3)
TB+
White/Blue (1)
Signal
Common
DC Common
PPC N
Yellow (5)
RA-
TXA/TDA/TXTXB/TDB/TX+
Color (RJ Pin)
Red (3)
White/Blue (1)
Not Used
External
Termination
Resistor
TATB+
Signal
Common
Not Used
Figure 2.72 Two Wire RS-485 Wiring
PPCs Mounted Close Together
In installations where two or more PPCs are close enough
together that using terminal strips or modular jack junction
boxes would result in greater lengths of flat cable than the
distance between the communications ports use modular jack
splitters and flat oval cables with RJ12 connectors on both
ends. See Figure 2.73.
485 Communications
232 Communications
serial port
shielded twisted pair cable
optically
isolating
232 to 485
converter
6-wire RJ12 splitter
PPC 1
PPC 2
PPC N
Figure 2.73 Connecting Several PPCs with Short
Cable Runs
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Signal Common
Each controller and the converter should be connected to the
signal common to insure they can properly interpret the signals
on the network. Pin #1 in the RJ12 connectors connects the
signal commons of all the PPCs to each other. At the converter
connect the signal common to the common of the converter’s DC
power supply.
The communications ports are optically isolated from the
sensors and the rest of the PPC circuitry, so connecting the
communications commons together will not create a ground
loop.
Termination
In some installations, particularly when transmission lines are
long, the transmission lines must be terminated. The receive
lines at the converter or host device should be terminated in the
converter, the connector to the host device, or the device itself.
Typically the converter documentation provides instructions
for termination.
The PPC receive lines can be terminated by setting a jumper on
the last PPC-2010 module. To terminate the lines for port 1, set
jumper JU1 on the last PPC-2010 module on the network to the
A position. This places a 120 ohm resistor across the receive
lines. To terminate the line for port 2, set jumper JU2 on the
last PPC-2010 module on the network to the A position. This
places a 120 ohm resistor across the receive lines. See PPC2010 Jumper Settings on page 18.
Alternately, the line may be terminated externally on the 485
terminal block by placing a termination resistor across the
receive line screw terminals near the last PPC. See Figure 2.70
on page 81. The value of the termination resistor should be
equal to the impedance of the communications cable used.
Values are typically 120 to 200 ohm.
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Modbus Network Address
For multiple PPC installations, each PPC-2010 must have a
unique network address. As many as 32 PPC systems may
communicate on a network. Both port 1 and 2 have the same
network address. Network addresses 1 through 4 can be set
using the rotary switch on the processor module.
Changed communication parameters do not take affect until
the controller resets or cycles power, and only with the
appropriate rotary switch settings on the Processor module.
Use rotary switch setting D and PPCComSu to program the
remaining addresses (5-32). See Setting Programmable
Modbus Addresses on page 87 for programming information.
NOTE!
Do not cycle power with the rotary switch set in positions
E-G unless specifically directed to do so. These
positions are used for clearing memory and other
functions. Parameter settings can be lost. See Chapter 4,
Troubleshooting, for more on these switch settings.
Table 2.31
PPC-2010 Rotary Switch
Configuration
Position
Network
Address
A
Fixed: 1
B
Fixed: 2
C
Fixed: 3
D
Programmable, Default: 4
E-G
N/A
H
Fixed: 1
Switch positions A-D select the following settings:
•
19.2 kbaud (programmable)
•
Even parity (fixed)
•
8 data bits (fixed)
•
1 stop bit (fixed)
Switch position H selects the following fixed settings:
•
19.2 kbaud
•
Even parity
•
8 data bits
•
1 stop bit
Switch settings E-G are reserved.
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Setting Programmable Modbus Addresses
Modbus addresses one through four may be set using the rotary
switch on the face of the PPC-2010 Processor Module. See
Modbus Network Address on page 86 for information on setting
the rotary switch. The following procedure describes how to set
other addresses:
∫
WARNING!
Power is shut off to the PPC during the following
procedure. Power cycling will interfere with process
control. Do not perform this procedure if interrupting
process control is not acceptable.
1.
Close AnaWin3 and LogicPro if either is running.
2.
Connect only the PPC to be configured to the computer on
which AnaWin3 is installed.
3.
Set the rotary switch on the Processor Module to position
H.
4.
Turn off power to the PPC system.
5.
Turn power on to the PPC system.
6.
Launch PPCComSu.
7.
Select the desired Baud Rate for each port.
8.
Select the desired Modbus address for the PPC system.
9.
Click the Send button.
10. Close PPCComSu.
11. Set the rotary switch on the Processor Module to position
D.
12. Turn off power to the PPC system.
13. Turn on power to the PPC system.
Once configured with unique addresses, as many as 32 PPC
controllers may be connected to the PC on a 485
communications network.
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3
Operating with AnaWin3
This section describes how to use your PPC system with
AnaWin3, the Watlow Anafaze HMI software. For hardware
installation and configuration information, refer to Chapter 2,
Hardware Installation. For AnaWin3 installation and user
information, refer to the AnaWin3 User’s Guide.
Type Definitions
In the following sections, a special font or typeface is used to
indicate text seen on the AnaWin3 screens:
LP Enable
Set this field to enable or disable the low process alarm. When
it is Enabled, the low process alarm activates if the process
variable (PV) dips below the LP Limit. The PV must rise above
the LP Limit plus the alarm deadband to be reset (cleared).
When this parameter is set to Disabled, the low process alarm
Figure 3.1
Sample Screen Text
The words LP Enable and LP Limit are shown as they appear in
AnaWin3.
Closed-Loop Control
The PPC-2000 closed-loop control program can control up to 48
channels. Closed-loop control refers to the control of an output
¡
based on feedback from a sensor or other signal.
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Feedback
Electrical signals from a sensor used to determine a control
output is feedback. The Input parameters determine how the
electrical signal is interpreted. Many standard sensor types are
pre-programmed into the PPC-2000 and can be selected during
setup. The controller interprets or scales the electronic signals
for these sensor types in engineering units (°F or °C). Other
sensor types may require user-supplied scaling information.
See Setting up User Selectable Linear Inputs on page 98.
In some cases the feedback signal may come from a value other
than a sensor input. Using a Soft Input, a logic program can
determine the feedback to a channel.
Control Algorithm
The PPC-2000 determines the appropriate output signal when
a set point is supplied and the controller is set to automatically
control a loop. The controller calculates the output based on the
feedback and the control algorithm. Each channel may use
either On/Off or any combination of Proportional, Integral and
Derivative (PID) control modes. See Control Algorithms on
page 220 for information on these control modes.
The PPC-2000 also includes a manual reset term that may be
used in conjunction with some of the PID modes. See Channels
on page 115 for more information on these parameters.
Control Output Signal Forms
The output level calculated by the controller is represented by
a percent (0-100%) of power to be applied. That value is applied
on a digital or analog output according to the user-selected
output type. See Output Control Forms on page 224 for more
information on the output types available.
Heat and Cool Outputs
The 48 control channels may each have one or two outputs.
Often a heater is controlled according to the feedback from a
thermocouple and, in that case, only one output is needed.
In other applications, it is possible that two outputs may be
used for control according to one input. If, for example, a
system with a heater and proportional valve that controls
cooling water flow are controlled according feedback from one
thermocouple, the channel has one input and two outputs.
In such systems, provisions are made in the control algorithm
to avoid switching too frequently back and forth between the
heat and cool outputs. The On/Off algorithm uses the Spread
parameter to prevent this bucking. See Channels on page 115
for more information. When PID control is used for one or both
channel outputs, both the spread and the PID parameters
determine when control switches between heating and cooling.
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Chapter 3: Operating with AnaWin 3
The PPC-2000 provides two methods for coordinating a heat
and a cool output driven by a single channel. The Control Type
parameter offers two choices PID1 and PID2. Table 3.1
describes these two algorithms.
Table 3.1
Doc.# 30002-00 Rev 2.3
Control Types PID1 and PID2
PID1
Only the heat output or the cool output is on at
any instant in time. The spread parameter provides a minimum switching hysteresis between
the two outputs. The channel will not switch
from heating to cooling until the heat integral
sum has dropped to zero, which is to say until
the process variable has been above set point
for some amount of time.
When the spread is set to zero, however, the
channel switches from heat to cool depending
on the PID calculation only, regardless of
whether the process variable is above the set
point.
PID2
When a channel uses the PID2 control type, the
cool output will come on whenever the process
variable is above the set point by more than the
spread setting. The cool output remains on until
the process variable drops to the set point. The
heat output operates as it would if the cool output were not enabled. This algorithm was developed for plastic extruders, but may be of benefit
whenever a load is typically heated but occasionally needs cooling.
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Setting up Control Channels
Closed-loop control channels can be set up in various ways in
the PPC-2000. The following procedure identifies the basic
steps:
1.
2.
3.
See Inputs on page 127 for descriptions of the input
parameters. On the Inputs spreadsheet:
a.
Choose the appropriate Input Type for the sensor connected to each analog input you have wired.
b.
Choose Units for each analog input.
c.
For any linear voltage, current, or pulse sensors, set
the linear scaling parameters (Input Signal Lo, Input Signal Hi, PV Lo, and PV Hi). See Setting up User Selectable
Linear Inputs on page 98.
See Channels on page 115 for descriptions of the channel
parameters. On the Channels spreadsheet:
a.
Choose the input in the PV Source field that you want
to monitor or use as feedback for closed-loop control
for each channel.
b.
Choose outputs in the Heat Output Dest and/or Cool Output Dest fields for each channel that you want to use
for closed-loop control.
c.
Choose a Heat/Cool Output Type for each output.
d.
Set the Heat/Cool Cycle Time for any outputs with Heat/
Cool Output Type set to Time Prop.
See Digital I/O on page 132 for descriptions of the digital
I/O parameters. On the Digital I/O spreadsheet:
a.
4.
92
Set the Direction for each I/O point to be used for control to Output.
On the Channels spreadsheet:
a.
Set the Heat/Cool Prop Band for any outputs with Heat/
Cool Output Type set to On/Off to 1.
b.
Set the PID parameters (Heat/Cool Prop Band, Heat/Cool
Derivative, and Heat/Cool Integral) for each output used
for PID control. The parameters may be determined
by performing an autotune on each channel or by other means. See Autotuning on page 93 or more information on autotuning.
c.
If both heat and cool outputs are used, set the Spread.
d.
Set the Set Point to the desired value and the Control
Mode to Auto to begin closed-loop control.
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Chapter 3: Operating with AnaWin 3
Autotuning
Autotuning is a process by which a controller determines the
correct PID parameters for optimum control.
Prerequisites
Before autotuning the controller, it must be installed with
control and sensor circuitry and the thermal load in place. It
must be safe to operate the thermal system, and the
approximate desired operating temperature (set point) must be
known.
The technician or engineer performing the autotune should
know how to use HMI software interface (e.g. AnaWin3) to
perform the following:
•
Set a channel’s set point
•
Change a channel’s control mode (manual, tune, auto)
•
Read and change the controller’s parameters
Background
Autotuning is performed at the maximum allowed output. If
you have set a limit, autotuning occurs at that value.
Otherwise, the control output is set to 100% during the
autotune. Only the heat output of a channel may be autotuned.
The PID constants are calculated according to process’s
response to the output. The channel need not reach or cross set
point to successfully determine the PID parameters. While
autotuning the controller looks at the delay between when
power is applied and when the system responds in order to
determine the integral term (Heat/Cool Integral). The controller
also looks for the slope of the rising temperature to become
constant in order to determine the proportional band (Heat/Cool
Prop Band). The derivative term (Heat/Cool Derivative) is derived
mathematically from the integral term.
When the controller has finished autotuning, the channel’s
control mode switches to Auto. If the process reaches 80% of the
set point or the autotuning time exceeds ten minutes, the
controller switches to Auto and applies the PID constants it has
calculated up to that point. If the tune can not get good data,
the controller returns to its previous control state (i.e., manual
mode) and leaves the PID parameters unchanged.
The Watlow Anafaze autotune is started at ambient
temperature or at a temperature above ambient. However, the
temperature must be stable and there must be sufficient time
for the controller to determine the new PID parameters.
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Tuning Method
The steps to autotune a channel are:
NOTE!
1.
In manual control set the set point to the value you will
use for the autotune.
2.
Note the value of the input filter.
3.
Set the input filter to 0 scans.
4.
Set the control mode to tune.
5.
Wait for the channel to autotune.
6.
Restore the input filter to its original value.
7.
Note the PID parameters for future reference.
A channel must be stable at a temperature well below
the set point in order to successfully autotune. The
controller will not complete tuning if the temperature
exceeds 75% of set point before the new parameters
are found.
Using AnaWin3 to Tune
The following procedure explains how to autotune a channel
using AnaWin3.
1.
Choose AnaWin3’s Channels spreadsheet screen and locate
the channel to be tuned.
2.
Ensure that the temperature is stable, and the channel is
in manual control mode (typically 0% heat output level).
3.
Note which input is used as the PV Source for the channel.
4.
On the Inputs spreadsheet, note the setting of the Input Filter
for that input, and then set it to 0 scans.
5.
On the Channels spreadsheet, increase the Set Point to a
value such that the temperature will not rise from 60% to
80% of that value in less than 10 seconds when heated at
100% output.
6.
Select Tune as the Control Mode.
When tuning is completed, the control mode changes to
Auto.
7.
Adjust the Set Point to the desired temperature.
8.
Restore the setting of the input filter to its original value.
ç
CAUTION!
94
Never set the set point above the safe operating limits
of your system.
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Chapter 3: Operating with AnaWin 3
Alarms
The controller has three different kinds of alarms: failed sensor
alarms, the global alarm, and process alarms. For information
on each of these alarms, refer to the following sections.
Failed Sensor Alarms
Failed sensor alarms indicate T/C breaks and failed RTDs due
to open leads.
When a channel is in Auto or Tune mode and a failed sensor
alarm occurs, the controller sets the channel to Manual control
at the Sensor Fail Heat% or Sensor Fail Cool% set in the Channels
spreadsheet.
A failed sensor alarm is only detected for an input that is
selected as the PV Source for a channel.
Global Alarm
The global alarm occurs when a channel alarm set to Alarm (not
Control) occurs or when there are any failed sensor alarms. If an
alarm occurs, the !Alarm screen displays the corresponding
alarm message. The global alarm output stays on until the
original alarm is acknowledged.
Process Alarms
Process alarms include high and low deviation and high and
low process alarms. Each of these alarms may be enabled or
disabled. If enabled, each may be set to function as an alarm or
a control. Refer to Alarms on page 123 for descriptions of the
parameters used to set up these alarms. Table 3.2 describes the
difference between Alarm type and Control type alarms.
Table 3.2
Doc.# 30002-00 Rev 2.3
Alarm Types
Alarm Type
Description
Alarm
Standard alarm function. Digital output, or Soft
Bool, if selected, activates on alarm, deactivates
when channel is not in alarm. Global alarm output
activates and requires alarm acknowledgment to
clear.
Control
Digital output, or Soft Bool, if set, activates on
alarm, deactivates when channel is not in alarm.
Global alarm output does not activate. No alarm
acknowledgment required to clear.
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High and low process and deviation alarms activate when the
process variable goes outside the limits set by the user. The
alarm remains active until both the process variable comes
within the limit and the deadband, and the alarm is
acknowledged.
Any digital output not used as a control output can be assigned
to a process alarm. The output activates when the alarm is
active. Set the Logic of outputs used with alarms to determine
whether the alarm output turns on or off when an alarm occurs.
An alarm output remains active only as long as the process
variable remains outside the alarm limit and deadband. Once
the process variable is within the limit and deadband, the
output reverts to the inactive state. No alarm acknowledgment
is required.
When the controller powers up or the set point changes,
deviation alarms set to alarm type do not activate until the
process variable comes within the deviation alarm band,
preventing deviation alarms during a cold start. Deviation
alarms set to control type activate whenever the process
variable is outside the deviation band.
High Process alarm on
High Process alarm off
High Process alarm limit
}Deadband
High Deviation
alarm on
SP + HD Offset
Set Point
}Deadband
High Deviation
alarm off
Low Deviation
alarm off
}Deadband
SP - LD Offset
Low Deviation
alarm on
}Deadband
Low Process alarm limit
Low Process alarm on
Figure 3.2
Low Process alarm off
Process Variable Alarms
Alarm Delay
The controller may be configured to delay alarm reporting.
Alarm Delay delays failed sensor alarms and process alarms for
the channel. Only alarms that are continuously present for
longer than the alarm delay time are reported.
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Setting up Process and Deviation Alarms
To enable alarms on the process variable for a channel follow
these steps. See Alarms on page 123 for descriptions of the
alarm parameters.
On the Alarms spreadsheet:
Doc.# 30002-00 Rev 2.3
1.
Set the Alarm Deadband.
2.
Set the Alarm Delay.
3.
For each alarm you wish to activate:
a.
Set the alarm limits in the corresponding fields: LP
Limit, LD Offset, HD Offset, HP Limit.
b.
Choose the alarm behavior by setting the corresponding field (LP Type, LD Type, HD Type, HP Type) to Alarm or
Control.
c.
Choose an available digital output to activate when
the alarm occurs, if desired, in the corresponding field
(LP Output Dest, LD Output Dest, HD Output Dest, HP Output
Dest).
4.
On the Dig I/O spreadsheet, set the Logic of each output
used for alarms as desired.
5.
Return to the Alarms spreadsheet. Enable the alarm by
setting the corresponding field (LP Enable, LD Enable, HD
Enable, HP Enable) to Enabled.
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Setting up User Selectable Linear Inputs
The Input Type and linear scaling fields (Input Signal Lo, Input
Signal Hi, PV Lo and PV Hi) appear on the Inputs spreadsheet.
Linear input types are used with sensors whose signals are
straight line (linear) functions of the quantity being measured.
For example, a sensor that supplies a voltage signal
proportional to the pressure it detects would use one of the
linear input types and the signal would be converted to a
process variable using the scaling values set on the Inputs
spreadsheet. To define the conversion function, the user
specifies two points on the line. See Figure 3.3.
20 PSI
PV Hi
Process
Variable
PV Lo
0 PSI
0V
Input Signal Hi 10V
Input Signal Lo
Sensor Input
Figure 3.3
98
Linear Input Example
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Choosing a Linear Input Type
To set up a linear input first choose an Input Type. There are
seven user selectable linear input types: three input types for
voltage signals, one for current, two for frequencies, and one for
counts. Pick an Input Type with the appropriate signal type
(voltage, current, frequency or counts). Also choose an Input Type
with the appropriate range and sensitivity for the sensor.
Generally, the appropriate Input Type for Soft Inputs is Linear
(Counts).
Table 3.3
Input Type
Range and Sensitivity of the
Custom Linear Input Types
Range
Input Resolution
Update
Rate
Linear -1 to 10 (V)
-1.000 to 10.000V
.0003V
*
Linear -0.1 to 1 (V)
-100.0 to 1000.0mV
.03mV
*
Linear -10 to 100 (mV)
-10.00 to 100.0mV
.003mV
*
Linear -2 to 20 (mA)
-2.000 to 20.000mA
.0006mA
*
Linear (Counts)
-32768 to 32767
Counts
1 count
4Hz
Linear 0 to 300.00 (Hz)
-327.68 to 327.67Hz
.04Hz
.04Hz
Linear 0 to 10k (Hz)
-32768 to 32767Hz
4Hz
4Hz
* Depends on module type. See Chapter 7, Specifications.
Setting Input Signal Lo and Input Signal Hi
After choosing the Input Type, set the Input Signal Lo and Input
Signal Hi. The Input Signal Lo is the lowest level signal the sensor
will supply. Typically this corresponds to the lowest process
variable to be measured. The Input Signal Hi is the highest level
signal the sensor will supply. Typically this corresponds to the
highest process variable to be measured.
Setting Engineering Units
Set the engineering units in which you will specify the PV Lo
and PV Hi. When used with linear inputs, the Units parameter is
for display only and has no effect on the process variable value
calculated or displayed.
Setting PV Lo and PV Hi
After setting the Input Signal Lo and Input Signal Hi, set the
corresponding PV Lo and PV Hi. The PV Lo is the process variable
measured when the sensor signal is at the level set in the Input
Signal Lo field. The PV Hi is the process variable measured when
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the sensor signal is at the level set in the Input Signal Hi field.
Both parameters are entered in units for the input.
Setting Decimal Places
Set the Decimal Places parameter to determine how many
decimal places are entered and displayed in the Process Variable,
Set Point and alarm limits (LP Limit, LD Offset, HD Offset, HP Limit)
for channels with the corresponding input selected as the PV
Source. The range for Decimal Places is limited by the range of
the PV to be displayed. The more decimal places to be
displayed, the smaller the range of PV that can be displayed;
therefore, the greater the difference between the PV Lo and PV
Hi, the fewer the decimal places that can be displayed.
Table 3.4 shows the maximum range for the PV for each
Decimal Places setting. For example, a sensor that measures
pressure over a range of 0-1000 Torr set up with a PV Hi equal
to 1000 Torr would limit the choices of Decimal Places to 0 or 1.
Two decimal places would not be possible when the PV must go
up to 1000 because when two decimal places are used the
highest PV that can be displayed is 327.67.
AnaWin3 automatically sets the Decimal Places to the maximum
allowable setting when the PV Lo or PV Hi is changed.
Table 3.4
100
PV Range permitted for various
Decimal Places Settings
Decimal
Places
PV Lo
minimum
PV Hi
maximum
0
-32768
32767
1
-3276.8
3276.7
2
-327.68
327.67
3
-32.768
32.767
4
-3.2768
3.2767
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Chapter 3: Operating with AnaWin 3
Linear 0-10Vdc Input Example
For a sensor that measures pressures from 0.0 to 15.0 psia and
outputs a 0-10Vdc signal, set the following parameters:
Table 3.5
Scaling Parameters for 0-10Vdc
Linear Input Example
Parameter
Input Type
Setting
Units
Linear -1 to 10 (v)
Units
psia
Input Signal Lo
0.000
V
Input Signal Hi
10.000
V
PV Lo
0.0
psia
PV Hi
15.0
psia
Decimal Places
1
Linear 4-20mA Input Example
For a sensor that measures relative humidity with a range of
0.00 to 100.00% and outputs a 4-20mA signal, set the
parameters according to Table 3.6.
Table 3.6
Scaling Parameters for 4-20mA Linear
Input Example
Parameter
Input Type
Units
Units
Linear -2 to 20 (mA)
%
Input Signal Lo
4.000
mA
Input Signal Hi
20.000
mA
PV Lo
0.00
%
PV Hi
100.00
%
Decimal Places
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Linear 0-1Vdc Input Example
For a sensor that measures light intensity between 0 and 500
Lumens and outputs a 0-1Vdc signal, set the following
parameters:
Table 3.7
Scaling Parameters for 0-1Vdc
Linear Input Example
Parameter
Setting
Input Type
Units
Linear -0.1 to 1 (v)
Units
Lumens
Input Signal Lo
0.0
mV
Input Signal Hi
1000.0
mV
PV Lo
0
Lumens
PV Hi
500.0
Lumens
Decimal Places
1
Process Variable Retransmit
This feature allows you to output signals representing the
process variables of source channels or other analog inputs on
the heat and cool outputs of a retransmit channel. The analog
input selected as the PV Source of the retransmit channel is
output on the heat output. The analog input selected as the Set
Point Source of the retransmit channel is output on the cool
output.
Heat/Cool Output (% of Full Scale)
The output signals are scaled using the Min Set Point and Max
Set Point and Heat/Cool Scale Hi and Heat/Cool Scale Lo
parameters. Figure 3.4 illustrates how the output signals are
related to the analog inputs by these scaling parameters.
Heat/Cool Scale Hi
Heat/Cool Scale Lo
Sensor Range
Low
Sensor Range
High
Analog Input Range (Engineering Units)
Figure 3.4
102
Min Set Point Max Set Point
Linear Scaling of the Analog Input
for Retransmit on the Heat or Cool
Output
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A channel cannot be used for closed-loop control when it is
configured as a retransmit channel.
Setting up Process Variable Retransmit
On the Channels spreadsheet for the channel that will output
the retransmit signal:
1.
Set the Control Type to PV Retransmit.
2.
Set the PV Source to the same setting as the PV Source parameter of the channel to be retransmitted or any other
analog input you want to retransmit.
3.
Set the Heat Output Dest to the PPC output on which you
want to retransmit the analog input.
4.
Set the Heat Output Type to a setting appropriate for the heat
output destination you chose in step 3.
5.
Set the Min Set Point to the minimum value of the analog
input that you want to retransmit.
6.
Set the Max Set Point to the maximum value of the analog
input that you want to retransmit.
To retransmit a second analog input on the same retransmit
channel with the same scaling:
1.
Set the Set Point Source to the second analog input to be
retransmitted.
2.
Set the Cool Output Dest to the PPC output on which you
want to retransmit
3.
Set the Cool Output Type to a setting appropriate for the cool
output destination you chose in step 2.
analog
If you do not wish to use the full range of the heat or cool output
type signal, the signal can be scaled:
Doc.# 30002-00 Rev 2.3
1.
Set the Heat Scale Lo to a percent of the range of the
selected heat output type. This is the signal level that will
be transmitted when the analog input selected as PV Source
is at the value you entered for Min Set Point.
2.
Set the Heat Scale Hi to a percent of the range of the selected
heat output type. This is the signal level that will be transmitted when the analog input selected as PV Source is at
the value you entered for Max Set Point.
3.
Set the Cool Scale Lo to a percent of the range of the selected cool output type. This is the signal level that will be
transmitted when the analog input selected as Set Point
Source is at a value you entered for Min Set Point.
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4.
Set the Cool Scale Hi to a percent of the range of the selected
cool output type. This is the signal level that will be transmitted when the analog input selected as Set Point Source is
at the value you entered for Max Set Point.
5. Set the Control Mode for the channel to Auto.
Process Variable Retransmit Example
In this example, channel 1 on the PPC measures a furnace
temperature with a thermocouple connected to an Analog
Input module and controls the firing of a power controller with
an output from the Processor module. The PPC is equipped
with an Analog Out module configured for current outputs.
Channel 2 is used to retransmit channel 1’s process variable
from one of these analog outputs to a chart recorder. The chart
recorder requires a 4-20mA dc signal. This signal range
represents 0 to 1000°F on the chart. Figure 3.5 illustrates this
example. Table 3.8 lists the settings used on the retransmit
channel.
Furnace
Channel 1 Input
PPC
Channel 2 Heat Output
To Chart
Recorder
Channel 1 Heat Output
Heater
Power
Control
Figure 3.5
Sample Application Using Process
Variable Retransmit
Table 3.8
Retransmit Channel Parameter
Settings
Parameter
104
Setting
Description
Control Type
PV Retransmit
This disables normal closed-loop control and
enables the PV retransmit feature.
Heat Output Dest
PPC1:AO 31.1
The first output on the Analog Output module with
its address set to 31 will be used to retransmit
channel 1’s process variable.
PV Source
PPC1:AI 1.1
The analog input to be retransmitted is from the
first sensor on the Analog Input module with its
address set to 1.
Heat Output Type
Analog 4-20mA
A 4-20mA signal is output representing the value
of the analog input.
Min Set Point
0°F
When the analog input value is less than or equal
to 0°F, channel 2’s output will be 4mA.
Max Set Point
1000°F
When the analog input value is equal to or greater
than 1000°F, channel 2’s output will be 20mA.
Control Mode
Auto
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Chapter 3: Operating with AnaWin 3
Cascade Control
Cascade control is used with thermal systems with long lag
times, which cannot be as accurately controlled with a single
control loop. To accomplish this, the output of the primary
channel is used to adjust the set point of the secondary channel.
The secondary channel executes the actual control.
In some applications, two zone cascade control systems are
used. In such systems, the primary channel’s output is used for
heat control and the secondary channel’s output is used for a
heat boost. Such arrangements are used in metal applications
such aluminum casting. The PPC’s cascade control feature
allows the primary channel’s output to be used both to
determine the secondary channel’s set point and as an actual
control output.
The secondary channel’s set point is determined according to
the heat and cool output values from the primary loop and the
user supplied Max Set Point and Min Set Point parameters. Figure
3.6 and Figure 3.7 on page 106 illustrate the relationship
between the primary channel’s output and the set point of the
secondary channel.
When the primary channel has both heat and cool outputs
enabled, the secondary channel’s set point is equal to the Min
Set Point setting when the cool output is at 100%. (See Figure
3.6) When the primary loop has only its heat output enabled,
the secondary channel’s set point is equal to the Min Set Point
setting when the heat output is at 0%. (See Figure 3.7 on page
106) In either case, the secondary channel’s set point is equal
to the Max Set Point setting when the heat output is at 100%.
Set Point of the Secondary Channel
(Engineering Units)
For a cool only primary channel, the secondary channel’s set
point is equal to the Min Set Point when the primary channel’s
cool output is at 100% and equal to the Max Set Point when the
primary channel’s cool output is at 0%.
Figure 3.6
Doc.# 30002-00 Rev 2.3
Max Set Point
Min Set Point
-100%
100%
Primary Channel’s Output (% of Full Scale)
How the Secondary Channel’s
Set Point is Determined When the
Primary Channel Has Heat and Cool
Outputs
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Set Point of the Secondary Channel
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Chapter 3: Operating with AnaWin 3
Max Set Point
Min Set Point
0%
100%
Primary Channel’s Heat Output (% of Full Scale)
Figure 3.7
How the Secondary Channel’s Set
Point is Determined When the Primary
Channel Has Only a Heat Output
Setting up Cascade Control
To setup cascade control:
1.
Set up the primary loop. See Cascade Control Example
below.
2.
Set up control for the secondary loop as you would for a
standard closed-loop application. See Setting up Control
Channels on page 92.
3.
On the secondary channel:
a.
Select the primary channel’s output (Channel # Out) for
the Set Point Source setting.
b.
Set the Min Set Point to the desired set point when the
primary channel’s output is at its minimum value.
c.
Set the Max Set Point to the desired set point when the
primary channel’s output is at its maximum value.
Cascade Control Example
The temperature of a tank of water is controlled by a heater
near the bottom of the tank. Two thermocouples measure the
water temperature. One is placed near the heater and is
referred to as the inner
outer TC. The other is placed in the center of
outer TC. The desired
the tank and referred to as the inner
outer TC is 150°F.
temperature of the water at the inner
outer TC is connected to the first input on the Analog Input
The inner
module. Output 22 on the Processor module is used to drive a
solid state relay power control. Figure 3.8 on page 107
illustrates this application.
106
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Chapter 3: Operating with AnaWin 3
Tank
Inner TC Channel 1 Input PPC
Outer
Channel 2 Heat Output
Inner
Outer TC Channel 2 Input
Heater
Power
Control
Figure 3.8
Sample Application Using
Cascade Control
outer TC is selected as the PV Source for
For cascade control the inner
the primary channel, and the inner
outer TC is selected as the PV
Source for the secondary channel. The secondary channel’s
output is used to control the heater.
An engineer familiar with the process has determined that as
outer (primary) TC drops from 150°F to
the temperature of the inner
140°F, the set point of the secondary channel should rise from
150°F to 190°F. Table 3.9 and Table 3.10 on page 108 list the
parameter settings for the primary and secondary channels.
The PID parameters of the primary channel must be tuned to
produce the desired effect on the secondary channel’s set point.
The primary channel typically uses proportional only control.
Disabling the integral and derivative components of PID
makes the secondary set point a predictable function of the
primary channel’s process variable.
The proportional band is selected so the set point of the
secondary channel has the desired relationship to the process
variable of the primary channel. In this application, the
proportional band of the primary channel is set to 10°F.
Table 3.9
Parameter
Primary Channel Parameter
Settings
Setting
Description
PV Source
PPC1:AI 1.1
The outer
inner TC is selected for the primary channel.
Set Point
150°F
The desired temperature at the inner TC.
Heat Prop Band
10
As the input drops 10°F, the output increases to 100%.
Heat Integral
0
Only proportional control is used.
Heat Derivative
0
Only proportional control is used.
Heat Output Dest
PPC1:Soft Bool
The primary output must be enabled, but is not used to drive
a load.
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Table 3.10
Parameter
Secondary Channel Parameter
Settings
Setting
Description
PV Source
PPC1:AI 1.2
The inner
outer TC is selected for the secondary channel.
Set Point Source
Channel 1 Out
For cascade control, the primary channel’s output
determines the secondary channel’s set point.
Min Set Point
150°F
When the primary channel’s output is 0% the
secondary channel’s set point is 150°F.
Max Set Point
190°F
When the primary channel’s output is 100% the
secondary channel’s set point is 190°F.
Heat Prop Band
Heat Integral
The secondary channel’s PID parameter values may be determined by
autotuning or manual tuning.
Heat Derivative
As the temperature in the middle of the tank (channel 1) drops,
the output goes up proportionally and the set point of channel
2 goes up proportionally. Thus heat is added to the system at
the element even though the temperature near the element
may have been at the desired temperature.
With proportional control, when channel 1 is at set point, its
output is 0%, and the set point of channel 2 is equal to the
desired temperature 150°F. If the temperature of the channel 1
drops below 149°F, the deviation results in a proportional
output of 10%. This results in an increase to the set point for
channel 2 equal to 10% of the set point range. The set point
range is defined by Max Set Point - Min Set Point. In this case the
range is 40°F (190°F - 150°F = 40°F). Ten percent of 40°F is 4°F.
So when the temperature at channel 2 drops 1 degree, channel
2’s set point increases by 4°F to 154°F. For every degree
channel 1 drops, channel 2’s set point increases by 4°F until
channel 1’s output is 100% and channel 2’s set point is 190°F.
At this point further decreases to channel 1’s process variable
have no additional affect on channel 2. Figure 3.9 on page 109
illustrates this relationship.
108
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Set Point of the Secondary Channel
(Engineering Units)
PPC-2000 User’s Guide
190°F
170°F
150°F
0%
50%
100%
Primary Channel’s Heat Output
(% of Full Scale)
150°F
145°F
140°F
Primary Channel’s Process Variable (°F)
Figure 3.9
The Secondary Channel’s Set Point is
Determined by the Primary Channel’s
Process Variable
Ratio Control
Using ratio control the process variable of one channel or any
analog input can determine the set point of another channel.
With ratio control the set point of the ratio channel is
calculated by multiplying the process variable value of the
master channel by a ratio then adding an offset.
Set Point Ratio and Set Point Offset are user set parameters. By
adjusting these parameters, you can adjust the relationship
between the process variable of the master channel and the set
point of the ratio channel. Figure 3.10 on page 110 illustrates
this relationship.
The set point of the ratio loop is limited by the settings of Max
Set Point and Min Set Point.
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Set Point of the Ratio Channel
(Engineering Units)
Chapter 3: Operating with AnaWin 3
Max Set Point
tio
ter
t+
Min Set Point
PV
P
*S
Ra
s
Ma
fse
SP
Of
SP Offset
Sensor
Range
High
Sensor
Range
Low
Master Channel’s Process Variable
(Engineering Units)
Figure 3.10 Relationship between the Master
Channel’s Process Variable and the
Ratio Channel’s Set Point.
Setting up Ratio Control
To set up ratio control:
110
1.
Set up the master channel as you would for a standard
closed-loop application. See Setting up Control Channels
on page 92.
2.
Set up the ratio channel as you would for a standard
closed-loop application.
3.
Make the following additional settings on the ratio
channel:
a.
For Set Point Source select the analog input that should
be used to determine the set point (the PV Source of the
master channel).
b.
Set the Set Point Ratio and Set Point Offset to create the
desired relationship between the analog input’s value
and the ratio channel’s set point.
c.
Set the Min Set Point to the lowest set point value the
ratio channel should ever have.
d.
Set the Max Set Point to the highest set point value the
ratio channel should ever have.
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Chapter 3: Operating with AnaWin 3
Ratio Control Example
A chemical process requires a formula of two parts water to one
part Potassium Hydroxide (KOH) to produce diluted Potassium
Hydroxide. The desired flow of water is 10 gallons per second
(gps) and the KOH should flow at 5 gps. Separate feeder pipes
for each chemical feed in to a common pipe. The flow rate of
each feeder pipe is measured by flow transducers providing 05Vdc signals to analog inputs on a PPC. Motorized valves
controlling the flow of each chemical are controlled by outputs
from the PPC. Figure 3.11 illustrates this application.
Water Input
KOH Input
PPC
Channel 1 Input
Flow Sensors
Channel 1 Output
Channel 2 Output
Channel 2 Input
Control Valves
Mixture Out
Figure 3.11 Sample Application Using Ratio
Control
In this application the first input on an Analog Input module is
set up to convert the linear voltage signals from the flow
sensors to gallons per second (gps). The water flow is controlled
by channel 1. The KOH flow is controlled by channel 2 and is
set up as the ratio channel. The KOH flow set point must be
half of the water flow value.
The process engineer doesn’t want the KOH set point to exceed
15 gps regardless of the water flow. Table 3.11 lists the channel
parameter settings for the ratio KOH channel.
Table 3.11
Parameter
Doc.# 30002-00 Rev 2.3
Ratio Channel Parameter Settings
Setting
Description
Set Point Source
PPC1:AI 1.1
The PV Source of the master channel.
Set Point Ratio
0.5
KOH should flow at one half of the water
flow rate.
Set Point Offset
0 gps
When water flow is 0 gps the KOH flow
should be 0 gps.
Min Set Point
0 gps
When the water flow is 0 gps the KOH flow
should be 0 gps.
Max Set Point
15 gps
The KOH set point will not exceed 15 gps.
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Differential Control
Differential control is a special case of ratio control. With
differential control, as with ratio, the set point of one channel
is determined by the process variable value of another channel.
The set point of the differential channel is calculated by adding
an offset (Set Point Offset) to the process variable value of the
master channel. The Set Point Ratio parameter is set to 1.
Remote Set Point
Remote set point is implemented in the PPC as a special case
of ratio control. As with ratio control, the set point of a channel
is set by multiplying an analog input value by a ratio (Set Point
Ratio) and adding an offset (Set Point Offset). Typically, however,
the analog input is not used as feedback for closed-loop control,
so there is no master channel. The Max Set Point and Min Set Point
parameters may be used to limit the set point value. Setup
remote set point according to the instructions for ratio control.
Logic Programs
The PPC-2000 is able to run not only the closed-loop control
program but also a user-written logic program. LogicPro is a
software program that runs under Windows95/98/NT. This
logic programming tool can be used to customize the function of
the PPC-2000 controller. Any of the digital and analog I/O as
well as all of the controller parameters can be accessed and
changed by user written logic programs. Logic programs are
stored along with the controller firmware in nonvolatile
memory. Consult the LogicPro User’s Guide for specific
instructions on how to write, compile and download logic
programs to the PPC-2000.
NOTE!
112
If an output variable in a logic program sets a value
using an IO Driver and IO Physical Address, the
associated register in the PPC-2000 cannot be written
to by the closed-loop control program, an HMI or any
other device.
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Chapter 3: Operating with AnaWin 3
Setting up Analog Inputs for Use with a Logic Program
The closed-loop control program updates any analog input
whether it is selected as the source for a channel or not. A logic
program can read and use the scaled Input Value from the
PPC’s datatable.
Set up the input as you would for a closed-loop control channel.
Select an Input Type, set the Units, and set scaling parameters if
using a Linear Input type. See Setting up User Selectable
Linear Inputs on page 98.
Setting up Outputs for Use with a Logic Program
Various types of conditioned outputs are available for logic
programs. These outputs include digital outputs conditioned
for time proportioning, DZC, SDAC and analog outputs scaled
in units of 0.0 to 100.0%. Conditioned outputs are not accessed
directly from the I/O physical address but rather through
channels’ output address. See Accessing Channel Parameters
with LogicPro on page 173. In order to have the logic program
write to these outputs, a loop must be set up with the output
destination, output type, and PV source. An unused input may
be used for the PV source. The loop should be in Manual mode.
The logic program can then write to the Heat or Cool Output%,
and the Heat or Cool Output Type will determine the kind of
conditioning performed.
Using Logic to Set an Analog Input
A logic program can set a process variable by outputting a value
to one of the Soft Input registers. The Soft Inputs show up on the
Inputs Spreadsheet and the list of options for PV Source in
AnaWin. To use the logic calculated value, select the Soft Input
as the PV Source and set up the channel as usual.
Starting and Stopping Logic Programs
After developing and downloading a logic program with
LogicPro, use the PPC Globals screen in AnaWin3 to start and
stop the logic program.
To start the logic program:
Doc.# 30002-00 Rev 2.3
1.
Select the View menu.
2.
Select PPC Globals.
3.
Double-click on the Start Logic Program button.
4.
Click on the Send button to command the PPC to start the
logic program
-orclick Cancel.
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ç
CAUTION!
The logic program will begin executing immediately
after clicking the Send button. Assure that the
equipment is in a safe condition to run logic.
To stop the logic program:
1.
Select the View menu.
2.
Select PPC Globals.
3.
Double-click on the Stop Logic Program button.
4.
Click the Send button to command the PPC to stop the logic
program
-orclick Cancel.
ç
CAUTION!
When stopping the logic program, all PPC digital outputs
are turned off. Outputs controlled by a closed-loop
control channel or a process alarm resume outputs on
the next scan. Ensure the logic program can be safely
stopped. If necessary, shutdown logic should be
integrated into the logic program.
To set whether the logic program runs on power up or not:
1.
Select the View menu.
2.
Select PPC Globals.
3.
Double-click the Logic Start State button.
4.
Select Startup Running or Startup Not Running.
5.
Click the Send button.
ç
CAUTION!
When the logic start state is set to Startup Running,
the logic program begins executing immediately on
power up. Ensure the equipment is in a safe condition
to run logic.
ç
CAUTION!
114
Closed-loop control is disabled during logic
downloads. Control modes are set to Off. Ensure that
all loops can be safely disabled before downloading
programs. After the program has been successfully
downloaded, loops remain in the Off mode.
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Chapter 3: Operating with AnaWin 3
Controller Parameters
View and set the parameters that determine how the PPC
interprets inputs, performs closed-loop control, operates
outputs, and monitors process variables for alarm conditions on
AnaWin3’s Spreadsheet Overview screen. Select the buttons on
the PPC tab to configure the seven spreadsheets (Channels,
Alarms, Inputs, Dig I/O, Outputs, Soft INT, and Soft BOOL), each
detailed below.
Global parameters are found on the PPC Globals screen under
AnaWin3’s View menu.
These parameters may also be accessed by a properly
configured operator interface terminal or third-party software.
Parameter definitions and ranges are defined below. When
using a third-party interface, refer to Chapter 5, Custom
Interfacing, for additional information.
Channels
Select the Channels button to configure or monitor PPC channel
parameters. Channel names are located in the first column;
each channel has a row of parameters associated with it. These
parameters control the behavior of the closed-loop control
channels and determine which sensor input and control
outputs are used.
Figure 3.12 Channels Spreadsheet
Channel names indicate the controller and the channel. For
example, PPC1:Channel 3 indicates the third channel on the first
PPC.
Each channel can have one input and one or two outputs (heat
and/or cool). Many of the channel parameters may be
individually set for the heat and cool outputs. For example, Heat
Prop Band is the proportional band for the heat output and Cool
Prop Band is the proportional band for the cool output.
A description for each parameter in Channels follows.
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Set Point
The set point is the desired value for the process variable. Use
this field to enter a set point for the selected channel. If the set
point entered is out of the defined range, the controller assigns
the closest number within the range.
Range: same as the range of the input type selected. See Table
3.14 on page 130.
Process Variable
This field shows the actual value measured by the sensor
attached to the input selected in the PV Source field for the
channel. The process variable is used in the channel’s feedback
calculation. This field is read-only.
Range: same as the range of the input type selected. See Table
3.14 on page 130.
Control Mode
This parameter indicates the mode of control:
•
Off — Select this option to turn off closed-loop control. Any
associated output will not be set by the closed-loop control
program and cannot be set manually or by a logic program.
•
Manual — Output is set by the user or a logic program. See
Heat Output% and Cool Output% earlier in this section.
•
Auto — Output is determined by the PID or on/off control
algorithm.
•
Tune — The loop determines and sets its proportional band,
derivative and integral parameters by setting the output
and measuring the system’s response. See Autotuning on
page 93.
Heat Output%
Enter a heat output value in percent when the channel is in
manual control mode, or monitor the output in automatic
control. For PID output types, the output is calculated based on
the heat PID parameters.
Range: 0.0% to 100.0%
Cool Output%
Enter a cool output value in percent when the channel is in
manual control mode, or monitor the output in automatic
control. For PID output types, the output is calculated based on
the cool PID parameters.
Range: 0.0% to 100.0%
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PV Source
Select the input used as the process variable for this channel.
Choose one of the displayed analog inputs. Use the scroll bar in
the pop-up window to view the available inputs.
Range: Not Assigned and all the analog inputs on the Inputs
spreadsheet.
Set Point Source
Select a setting to determine how the set point for the channel
is set. Select User for normal closed-loop control applications.
Select a channel output (Channel # Out) for cascade control.
Select an analog input for ratio control, differential control,
remote set point, or process variable retransmit.
Range: User, Channel 1 Output to Channel 48 Output, and all analog
inputs on the Inputs spreadsheet.
Min Set Point
Enter the minimum value the PPC should accept for the set
point of the channel. This parameter is also used to scale a
cascade channel. (See Cascade Control on page 105).
Range: The range is the same as that of the input type for the
channel.
Max Set Point
Enter the maximum value the PPC should accept for the set
point of the channel. This parameter is also used to scale a
cascade channel. (See Cascade Control on page 105).
Range: The range is the same as that of the input type for the
channel.
Set Point Ratio
For ratio control, differential control, and remote set point
applications, set the ratio by which the analog input value
selected as the Set Point Source is multiplied to calculate the set
point. (See Ratio Control on page 109, Differential Control on
page 112, and Remote Set Point on page 112.)
Range 0.01 to 300.0
Set Point Offset
For ratio control, differential control, and remote set point
applications set the offset which is added to the product of the
analog input value selected as the Set Point Source and the Set
Point Ratio to calculate the set point. (Ratio Control on page 109,
Differential Control on page 112, and Remote Set Point on page
112.)
Range: -32768 to 32767 (Decimal placement depends on the
Input Type selected.) See Table 3.15 on page 130.
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Control Type
Select the function of the channel. Refer to Table 3.12. Refer to
Heat and Cool Outputs on page 90 for more on PID1 and PID2.
Table 3.12
AnaWin3 Control Types
Control Type
Description
PID1
Heat and Cool outputs used to control.
Only one output may be on at a time.
PID2
Heat and Cool outputs used to control.
Both outputs can be on at the same time.
Retransmit
Choose this type to use the channel to
retransmit one or two analog inputs.
Heat/Cool Prop Band
Set the proportional band. Larger numbers result in less
proportional action for a given error or deviation from set point.
This parameter is set in engineering units.
Range: depends on the input type. See Table 3.15 on page 130.
Heat/Cool Integral
Enter the integral term value which controls the amount of
influence the history of error has on the output. Increasing the
integral value decreases the integral contribution to the
output. Entering an integral value of 0, however, yields no
integral action. This value is in seconds per repeat.
Range: 0 to 6000 seconds/repeat
Heat/Cool Derivative
Enter the derivative term value which controls the amount of
influence the rate of change of the error has on the output. A
greater value yields a greater derivative action. The derivative
constant is in units of seconds.
Range: 0 to 255 seconds
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Heat/Cool Man Reset
Enter a value to add to the PID output calculation. When the
corresponding Integral is set to zero, the value substitutes for
the integral sum portion of the feedback calculation. In this
case, the output equals the heat/cool manual reset value when
the process variable is at set point. When the integral value is
set to a value other than zero, the manual reset value is added
to the result of the PID calculation and, thereby, shifts the
output variable.
Range: 0.0% to 100.0%
Heat/Cool Output Dest
Select the output destination to specify the I/O point used for
the control output. This is the output for the closed-loop control
channel. Selecting Not Assigned indicates no output is to be used,
and is an appropriate setting for monitor-only channels.
If both heat and cool output destinations are set, the channel
performs bimodal control. See Heat and Cool Outputs on page
90 for more information on this type of control.
Range: Any output found on the Dig I/O or Outputs spreadsheet
or any of the Soft Bool or Soft Int registers.
Heat/Cool Output Type
This field specifies the type of output signal and determines
whether the PID or on/off control algorithm is used for the
channel. Refer to AnaWin3 Output Types on page 120 for a
description of the output type options.
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Table 3.13
Output Type
AnaWin3 Output Types
Description
Function
Time Prop
digital, time proportioned
Percent output converted to a percent duty
cycle over the user-selected fixed time.
DZC
digital, distributed zero crossing
(not available for mechanical relay outputs)
Output on/off state calculated for every AC
line cycle.
On/Off
digital, on/off
Output either full ON or full OFF
Internal Count
Integer register
Calculated output may be used by a logic
program
Analog 0-20mA
Analog output type, 0-20mA
Analog 4-20mA
Analog output type, 4-20mA
Analog 0-5Vdc
Analog output type, 0-5Vdc
Analog 1-5Vdc
Analog output type, 1-5Vdc
Analog 0-10Vdc
Analog output type, 0-10Vdc
SDAC 0-20mA
Serial digital-to-analog converter, 0-20mA
SDAC 4-20mA
Serial digital-to-analog converter, 4-20mA
SDAC 0-5Vdc
Serial digital-to-analog converter, 0-5Vdc
SDAC 1-5Vdc
Serial digital-to-analog converter, 1-5Vdc
SDAC 0-10Vdc
Serial digital-to-analog converter, 0-10Vdc
Analog output using a PPC-2030 or PPC2050 through 2053
Analog output using a digital output from
the PPC-2010 module connected to a
peripheral SDAC module
Heat/Cool Cycle Time
Specify the time base for time proportional outputs. The output
percentage is proportioned over this time period. For example,
a 50% output with a 10-second cycle time is on for 5 seconds and
off for 5 seconds. Heat/Cool Cycle Time only affects control when
the corresponding output type is set to Time Prop (digital time
proportioning).
Range: 0 to 255 seconds
Heat/Cool Curve
Indicate which output scaling method is to be used.
•
Straight Linear — Output is unaffected and is set as
calculated by the closed-loop PID calculation.
•
Lag Curve A — Output is reduced somewhat from calculated
value.
•
Lag Curve B — Output is further reduced from calculated
value.
Straight linear is used for most applications. Lag curves are
usually used in plastic extruder applications.
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100
100
90
80
80
Actual
Output
Applied 60
(%)
Linear
79
70
66
62
60
50
A
48
44
40
40
36
30
20
20
10
3
0
19
13
8
2
19
12
7
4
29
27
B
Calculated Closed-Loop Control Action (%)
100
Figure 3.13 Output Scaling (Heat/Cool) Curves
With Lag Curve A or Lag Curve B selected, a PID calculation
results in a lower actual output level than the linear output
requires. This output is used when the response of the system
to the output device is non-linear.
Heat/Cool Output Filter
Use this menu to damp the heat or cool output’s response. The
output responds to a step change by going to approximately
2/3 of its final value within the number of scans set here. A
larger number yields a slower, or more damped, control
response to changes in the calculated output.
Range: 0 to 100 scans; 0 disables the filter
Auto Heat/Cool Limit
Use this menu to limit the control output for a channel’s heat
and cool outputs. This limit may be continuous, or it may be in
effect for a specified number of seconds (see Heat/Cool Limit Time
below). If you choose a timed limit, the heat/cool limit restarts
when the controller powers up and when the channel changes
from Manual to Automatic control. The heat/cool limit only
affects channels under automatic control. It does not affect
channels under manual control.
Range: 0.0% to 100.0%
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Heat/Cool Limit Time
Set a time limit for the Auto Heat/Cool Limit. If set to 0, the heat/
cool limit is in affect whenever the channel is in automatic
control.
Range: 0 to 32767 seconds
Heat/Cool Scale Lo
A control output may be linearly scaled by setting this
parameter. Enter the percent of the output range of the
selected Heat/Cool Output Type that should correspond to a
calculated Heat/Cool Output% of 0%.
Range: 0.0% to 100.0%
Heat/Cool Scale Hi
A control output may be linearly scaled by setting this
parameter. Enter the percent of the output range of the
selected Heat/Cool Output Type that should correspond to a
calculated Heat/Cool Output% of 100%.
Range: 0.0% to 100.0%
Sensor Fail Heat% / Cool%
When a failed sensor alarm occurs on a channel under
automatic control, that channel goes to manual control at the
percent power output set here. Enter the default percentage to
which a channel’s output is set if its input sensor fails.
Range: 0.0% to 100.0%
Spread
Enter the offset between heat and cool modes when both heat
and cool outputs for a channel are used. The spread is also the
switching hysteresis for on/off channels with Output Type set to
On/Off. The spread is in the channel’s engineering units.
Range: same as the range of the input type selected. See Table
3.14 on page 130.
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Heat/Cool Scale Lo
Set this parameter in conjunction with Heat/Cool Scale Hi to scale the output or to change the control
action. (See table 3.x.) Enter the value, as a percent of range, that the output should approach as the
process variable approaches the set point from below for a heat output or from above for a cool output.
See Figure 3.x.
The default and typical value is 0%. For example, as a heater raises the temperature of a load towards
set point, the output decreases toward 0%. In some cases it is desirable that the output never reach 0%,
in that case enter a minimum value greater than 0%.
Range: 0.0 to 100.0%
Heat/Cool Scale Hi
Set this parameter in conjunction with Heat/Cool Scale Lo to scale the output or to change the control
action. (See table 3.x.) Enter the value, as a percent of range, that the output should approach as the
process variable moves away from the set point either upward for a heat output or downward for a cool
output. See Figure 3.x.
The default and typical value is 100%. For example, as the temperature of a heated system drops the
controller increases its output toward 100%. In some cases it is desirable that the output never reach
100%, in that case enter a maximum value less than 100%. See also Auto Heat/Cool Limit.
Range: 0.0 to 100.0%
Note
Sometimes it is necessary for a heat output to increase as the process variable approaches the set point
from below. In such cases the Heat/Cool Scale Lo value is set above the Heat/Cool Scale Hi parameter.
(See Direct Heat in Table 3.x.) For example, in some systems heat is added outside the control loop and
the heat output controls a cooling water flow. In such a system as the temperature rises to set point, the
output increases to flow more water and slow the heating process.
Table 3.x Output Scaling Parameters Settings and Control Action
Output Control Action
Scale Lo
Scale Hi
Note
Heat
Reverse (Default)
0%
100% As the process variable increases,
Cool
Reverse
100%
0% the output decreases.
Heat
Direct
100%
0% As the process variable increases,
Cool
Direct (Default)
0%
100% the output increases.
CAUTION
When a Heat/Cool Scale Lo parameter is set to a value greater than the corresponding Heat/Cool Scale
Hi, the Heat Output % or Cool Output % values are inversely related to the actual output signal. In this
case when the Heat/Cool Output % indicates 0% the output is fully on regardless of whether the Control
Mode is set to Auto, Manual or Tune. Always remove power from the controller before servicing any
components.
Figure 3.x Heat and Cool Scaling Parameters
Process Variable (Units)
Output (%)
Set Point + Cool Prop Band
Cool Scale Hi
Cool
Cool Scale Lo
Set Point
Heat Scale Lo
Heat
Set Point - Heat Prop Band
Heat Scale Hi
Time
As the process
variable increases
toward set point,
the heat output
trends toward the
Heat Scale Lo
value
As the process
variable increases
away from set
point, the cool
output trends
toward the Cool
Scale Hi value
As the process
variable decreases
toward set point,
the cool output
trends toward the
Cool Scale Lo
value
As the process
variable decreases
away from set
point, the heat
output trends
toward the Heat
Scale Hi value
PPC-2000 User’s Guide
Chapter 3: Operating with AnaWin 3
Alarms
Parameters on the Alarms spreadsheet enable and set the
behavior of the process and deviation alarms for each channel.
Figure 3.14 Alarms Spreadsheet
Select the Alarms button to configure or monitor PPC alarm
parameters. Channel names are located in the first column;
each channel has a row of associated alarm parameters. For
example, PPC1:Channel 3 indicates PPC #1 and channel #3.
HP Limit
Enter the value at which you want the high process alarm to
activate. The high process alarm activates when the process
variable (PV) goes above the high process set point. The PV
must drop to the alarm set point minus the alarm deadband for
the alarm to clear.The default high process alarm set point is 0.
Range: same as the range of the input type selected. See Table
3.15 on page 130.
HP Type
Select the function of the high process alarm. See Process
Alarms on page 95 for a description of the settings.
Range: Alarm or Control
HP Enable
Set this field to enable or disable the high process alarm. When
it is Enabled, the high process alarm activates if the process
variable (PV) rises above the HP Limit. The PV must drop below
the HP Limit minus the alarm deadband to be reset (cleared).
When this parameter is set to Disabled, the high process alarm
does not occur.
Range: Enable or Disable
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HP Output Dest
Choose a digital output to toggle when the high process alarm
occurs. This may be any available hardware output or Soft
Boolean register accessible by the logic program. The default
for this parameter is Not Assigned. Outputs that are already
assigned to control output destinations will be rejected. The
same output may not be used for multiple alarm output
destinations.
Range: Not Assigned, or any of the digital outputs on the DigI/O
spreadsheet, or any of the Soft Bool registers.
HD Offset
Designate an offset value that determines the high deviation
alarm limit relative to the current set point. The high deviation
alarm occurs when the process variable is greater than the
channel set point plus this value. The alarm limit changes
when the set point changes. The default high deviation alarm
offset is 0.
Range: same as the range of the input type selected. See Table
3.15 on page 130.
HD Type
Set the high deviation alarm function. See Process Alarms on
page 95 for a description of the settings.
Range: Alarm or Control
HD Enable
Set this field to enable or disable the high deviation alarm.
When it is Enabled, the high deviation alarm activates if the
process variable (PV) rises above the set point by more than the
HD Offset. The PV must drop below the high deviation limit
minus the alarm deadband to be reset (cleared). When this
parameter is set to Disabled, the high deviation alarm does not
occur.
Range: Enable or Disable
HD Output Dest
Choose a digital output to toggle when the high deviation alarm
occurs. This may be any available hardware output or Soft
Boolean register accessible by the logic program. The default
for this parameter is Not Assigned. Outputs that are already
assigned to control output destinations will be rejected. The
same output may not be used for multiple alarm output
destinations.
Range: Not Assigned, or any of the digital outputs on the DigI/O
spreadsheet, or any of the Soft Bool registers.
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LD Offset
Designate an offset value that determines the low deviation
alarm limit relative to the current set point. The low deviation
alarm occurs when the process variable is lower than the
channel set point less this value. The alarm limit changes when
the set point changes. The default low deviation alarm offset is
0.
Range: same as the range of the input type selected. See Table
3.15 on page 130.
LD Type
Set the function of the low deviation alarm. See Process Alarms
on page 95 for a description of the settings.
Range: Alarm or Control
LD Enable
Set this field to enable or disable the low deviation alarm.
When it is Enabled, the low deviation alarm activates if the
process variable (PV) dips below set point by more than the LD
Offset. The PV must rise above the low deviation limit plus the
alarm deadband to be reset (cleared). When this parameter is
set to Disabled, the low deviation alarm does not occur.
Range: Enable or Disable
LD Output Dest
Choose a digital output to toggle when the low deviation alarm
occurs. This may be any available hardware output or Soft
Boolean register accessible by the logic program. The default
for this parameter is Not Assigned. Outputs that are already
assigned to control output destinations will be rejected. The
same output may not be used for multiple alarm output
destinations.
Range: Not Assigned, or any of the digital outputs on the DigI/O
spreadsheet, or any of the Soft Bool registers.
LP Limit
Set the low process alarm limit. An alarm occurs when the
process variable is less than this value. This value does not
change when the set point changes. The default low process
alarm set point is 0.
Range: same as the range of the input type selected. See Table
3.15 on page 130.
LP Type
Select the function of the low process alarm. See Process
Alarms on page 95 for a description of the settings.
Range: Alarm or Control
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LP Enable
Set this field to enable or disable the low process alarm. When
it is Enabled, the low process alarm activates if the process
variable (PV) dips below the LP Limit. The PV must rise above
the LP Limit plus the alarm deadband to be reset (cleared). When
this parameter is set to Disabled, the low process alarm does not
occur.
Range: Enable or Disable
LP Output Dest
Choose a digital output to toggle when the low process alarm
occurs. This may be any available hardware output or Soft
Boolean register accessible by the logic program. The default
for this parameter is None. Outputs that are already assigned
to control output destinations will be rejected. The same output
may not be used for multiple alarm output destinations.
Range: None, or any of the digital outputs on the DigI/O
spreadsheet, or any of the Soft Bool registers.
Alarm Deadband
Set this parameter to prevent process and deviation alarms
from toggling on and off when the process variable is near the
alarm limit set point. For high alarms the deadband is below
the set point; for low alarms the deadband is above the set
point. An alarm that occurs when the process variable crosses
the alarm set point will not clear until the process returns
within the alarm set point, and the deadband value. The
default alarm deadband is 2.
Range: Depends on the input type selected.
Alarm Delay
Set this parameter to delay alarm reporting. Use this feature to
prevent false alarms due to noise on sensors. The alarm delay
applies to failed sensor alarms and process and deviation
alarms. Only alarms that are present for longer than alarm
delay time are reported.
Range: 0 to 100 seconds
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Inputs
Parameters on the Inputs spreadsheet determine how
measurements of signals from sensors attached to the analog
input modules are read and scaled into engineering units for
use by closed-loop control channels, monitor channels and logic
programs.
Figure 3.15 Inputs Spreadsheet
PPC1:AI 1.3
module I/O number
module address
module type abbreviation
controller number
Figure 3.16 Analog Input Names
Select the Inputs button to configure or monitor PPC input
parameters. Input names are located in the first column; each
input has a row of associated parameters. The default input
name identifies the PPC, module and module I/O number.
Double-click on a parameter to edit it.
The module type is indicated in the default input name. Module
types are abbreviated. See Table 3.14 for a description.
Table 3.14
Module Abbreviations Seen on the
Inputs Spreadsheet
Module Type
PPC-202x Analog Input
Abbreviation
AI
PPC-2030 Encoder Input Analog Output
EIAO
PPC-2010 Processor
Proc
PPC-2040 Digital I/O
DIO
For example, PPC1:AI 1.3 indicates PPC #1, the analog input
module with address 1, and input #3. For a description of
module addresses, see Module Addresses on page 17 for a table
that correlates the module I/O numbers with screw terminals
on the AITB, see Table 2.13 on page 48.
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The Processor module, Digital I/O, and Encoder In Analog
Output modules accept pulse inputs. Both the count and
frequency of each pulse signal are listed as inputs. Pulse input
names identify the PPC, module, I/O type and module I/O
number and indicate counter (C) or frequency (F). See example
in Figure 3.17.
PPC1:Proc 0.1.2 F
Frequency/Counter
module I/O number
I/O type
module address
module type
controller number
Figure 3.17 Pulse Input Names
Soft inputs appear on the Inputs spreadsheets. A soft input can
be selected as the PV Source of a channel when that channel is
to get its feedback from a logic program. There are 50 soft
inputs in a PPC. These inputs are not associated with any
physical I/O. A value written to a soft input by a logic program
is treated as a raw input and is scaled and filtered according to
its input parameter settings. If a soft input is selected as a PV
Source, the input type will be set automatically to Linear
(counts). Figure 3.18 illustrates how soft input names appear in
the spreadsheet.
PPC1:Soft Input1
soft input number
controller number
Figure 3.18 Soft Input Names
Channel outputs appear on the Inputs spreadsheets. A channel
output can be selected as the Set Point Source of a channel for
cascade control applications. (See Cascade Control on page
105.) There are 48 channel outputs in a PPC. These inputs get
their value from the sum of the Heat Output % and Cool Output %
of each channel. Channel outputs are treated as raw inputs and
are scaled and filtered according to the input parameter
settings. Figure 3.19 on page 129 illustrates how channel
output names appear in the spreadsheet settings.
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PPC1:Channel 1 Output
channel number
controller number
Figure 3.19 Channel Output Names
Table 2.15 on page 56 correlates module I/O numbers with
screw terminals on the EITB.
Input Value (PV)
This field displays the scaled and filtered value measured by
the sensor attached to the corresponding input. This field is
read-only.
Range: Depends on input type selected. See Table 3.15.
Input Status
This field displays information about the sensor.
•
No Problem — sensor is functioning as expected.
•
Open Sensor — T/C or RTD not properly connected.
•
CMO — Common Mode Overvoltage, there is too much
noise on the sensor to make an accurate reading.
•
Shorted RTD sensor.
•
Ambient temperature error — temperature is outside
controller's operating range.
If two or more problems occur simultaneously the Input Status
lists the errors.
Input Type
Choose the input type appropriate for the sensor connected to
the corresponding input. Table 3.14 lists the choices available.
Select No Input if no sensor is attached to the input.
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Table 3.15
Input Types
Input Type
130
Sensor
Range
Low
Sensor
Range
High
No Input
N/A
N/A
Volts: -1 to 10V
-1Vdc
10Vdc
Volts: -0.5 to 5V
-0.5Vdc
5Vdc
Volts: -0.1 to 1V
-0.1Vdc
1Vdc
Volts: -50 to 500mV
-50mVdc
500mVdc
Volts: -10 to 100mV
-10mVdc
100mVdc
Volts: -5 to 50mV
-5mVdc
50mVdc
Linear -1 to 10 (V)
-1.000Vdc
10.000Vdc
Linear -0.1 to 1 (V)
-100.0mVdc
1000.0mVdc
Linear -10 to 100 (mV)
-10.00mVdc
100.00mVdc
Linear -2 to 20 (mA)
-2.000mA
20.000mA
Linear (Counts)
-32768 Counts 32767 Counts
Linear 0-300 (Hz)
-32768Hz
32767Hz
Linear 0 to 10K (Hz)
-327.68Hz
327.67Hz
Current, 0-20mA
0mA
20mA
Current, 4-20mA
4mA
20mA
Reserved
N/A
N/A
Counter
-32768 Counts 32767 Counts
Frequency
-10000Hz
10000Hz
B T/C
32°F
3308°F
C T/C
32°F
4200°F
D T/C
32°F
4200°F
E T/C
-454°F
1221°F
J T/C
-346°F
1598°F
J T/C without open sensor detection -346°F
1598°F
K T/C
-454°F
2249°F
K T/C without open sensor detection -454°F
2249°F
N T/C
-454°F
2372°F
R T/C
-58°F
3215°F
S T/C
-58°F
3215°F
T T/C
-454°F
752°F
F T/C (Platinel2)
32°F
2250°F
G T/C
32°F
4200°F
RTD 100 Ohm Plat
-418°F
521°F
RTD 100 Ohm Plat High
-418°F
1562°F
100K Ohm Thermistor
-25°F
327°F
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NOTE!
The counter and frequency inputs update four times
per second (4Hz), except the Linear 0-300 (Hz) input
type, which updates once every 25 seconds (.04Hz).
The update rate of all other input types depends on
the module. See Chapter 7, Specifications.
Units
For temperature sensors, choose the temperature scale for the
input value. For custom linear and pulse type inputs, choose a
three-character description of the input’s engineering units.
Table 3.16
Units
Input
Character Sets for Units
T/C and RTD
°F or °C
Linear or Pulse
0 to 9, A to Z,%, /, degrees, space
Decimal Places
Set the Decimal Places parameter to determine how many
decimal places are entered and displayed in the Process Variable,
Set Point and alarm limits for channels with the corresponding
input selected as the PV Source. The range for Decimal Places is
limited by the range of the PV to be displayed. The more
decimal places to be displayed, the smaller the range of PV that
can be displayed. The greater the difference between the PV Lo
and PV Hi the fewer the decimal places that can be displayed.
Input Filter
Set the filter value to damp changes to the process variable.
The process variable used to calculate the outputs responds to
a step change by going to approximately 2/3 of its final value,
within the number of scans set here. A larger number yields a
slower, or more damped, response to changes as measured by
the sensor.
Range: 0 to 255 scans. 0 disables the filter.
PV Offset
Enter a number to adjust the reading of an Input Value. For
T/Cs and RTDs, the value entered here is added to the
temperature measurement. For counter inputs, the value set
here is loaded as the Input Value when it is entered. Enter 0 to
reset a counter.
Range: -32768 to 32767 (Decimal placement depends on Input
Type selected).
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Input Signal Lo
For linear inputs (see Setting up User Selectable Linear Inputs
on page 98), enter the sensor signal level that corresponds to
the low process value entered in PV Lo (see below). The input
Signal Lo is entered in the units of the Input Type.
Range: Depends on Input Type selected. See Table 3.15 on page
130.
Input Signal Hi
For linear inputs (see Setting up User Selectable Linear Inputs
on page 98), enter the sensor signal level that corresponds to
the high process value entered in PV Hi (see below). The Input
Signal Hi is entered in the units of the Input Type selected.
Range: Depends on Input Type selected. See Table 3.15 on page
130.
PV Lo
For linear inputs (see Setting up User Selectable Linear Inputs
on page 98), enter a low process value. Set this parameter to the
value to be displayed when the signal is at the level set in Input
Signal Lo (see above). The Input Value (PV) will not indicate a
value less than the PV Lo regardless of how low the sensor
signal dives. The set point and alarm limits for an associated
channel cannot be set to values less than PV Lo.
Range: Depends on Decimal Places. See Table 3.4 on page 100.
PV Hi
For linear inputs (see Setting up User Selectable Linear Inputs
on page 98), enter a high process value. Set this parameter to
the value to be displayed when the signal is at the level set in
Input Signal Hi (see above). The Input Value (PV) will not indicate a
value greater than the PV Hi regardless of how low the sensor
signal rises. The set point and alarm limits for an associated
channel cannot be set to values higher than PV Hi.
Range: Depends on Decimal Places. See Table 3.4 on page 100.
Digital I/O
Parameters on the Dig I/O spreadsheet determine the state and
behavior of digital or discrete inputs and outputs found on the
PPC’s processor and digital I/O modules.
Figure 3.20 Dig I/O Spreadsheet
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Select the Dig I/O button to configure or monitor PPC Digital
I/O parameters.
I/O names are located in the first column. The I/O names
identify each I/O point. Names for Processor (PPC-2010) and
Digital I/O (PPC-204X) modules differ slightly from Digital Out
(PPC-206X) and Digital In (PPC-207X) names. Processor and
Digital I/O names include an I/O type designator because those
modules support digital, count, and frequency types. For
example, a Processor I/O name, PPC1:Proc 0.0.2 indicates PPC
#1, digital I/O on the processor module (which has module
address 0), I/O type (0=digital) and point #2. See Figure 3.21 for
a breakdown of this example. Alternatively, the Digital Out
I/O name, PPC1:DO 41.2 indicates PPC #1, Digital Out module
with address 41, and point #2. See Figure 3.22 for a breakdown
of the example. See Table 3.17 on page 134 for module type
abbreviations.
See Table 2.10 on page 39 for a list of module I/O numbers
corresponding to the TB50 terminals.
PPC1:Proc 0.0.2
module I/O number
I/O type
module address
module type
controller number
Figure 3.21 PPC-2010 and PPC-204X Digital I/O
Names
PPC1: DO 41.2
module I/O number
module address
module type
controller number
Figure 3.22 PPC-206X and PPC-207X Digital I/O
Names
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Table 3.17
Module Abbreviations Seen on the
Digital I/O Spreadsheet
Module Type
Abbreviation
PPC-2010 Processor
Proc
PPC-204x Digital I/O
DIO
PPC-206x Digital Out
DO
PPC-207x Digital In
DI
State
This field indicates the state of the digital I/O in the system.
I/O points configured as inputs are read-only.
Range: 0 or 1
NOTE!
The state must be interpreted in terms of the Logic
setting in order to know if the I/O point is on or off. For
example, if the state of an I/O point is 1 and the Logic
is 1=On, then the I/O point is On (low).
Direction
Select whether the flexible I/O points are being used as inputs
or outputs. All flexible I/O points default to inputs.
Range: Input or Output
Logic
Specify the active, true level (ON state) for each digital I/O.
Range: 1 = On or 0 = On
Function
Indicates how an I/O point is being used in the system.
Table 3.18
134
Function Values
Not Assigned
Output not used for control or alarm
Control Output
Output selected in Heat/Cool Output Dest
field on the Channels spreadsheet.
Alarm Output
Selected in LP, LD, HD or HP Output Dest
field on the Alarms spreadsheet.
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Outputs
The Outputs spreadsheet lists the output value for each of the
analog outputs. Output behavior is set by the parameters of the
channel with the output set as the output destination on the
Channels spreadsheet.
Figure 3.23 Outputs Spreadsheet
Select the Outputs button to monitor the analog output values.
Analog Output names are located in the first column. The
Analog Output names identify the module, I/O type (if
necessary), and module I/O number. The module type is
abbreviated in the default I/O name. For example, PPC1:EIAO
11.3.2 indicates PPC #1, the encoder input analog output
module with module address 11, I/O type (3 = analog out), and
output #2. See Figure 3.24 and Table 3.19.
PPC1:EIAO. 11. 3. 2
module I/O number
I/O type
module address
module type
controller number
Figure 3.24 Analog Output Names
Table 3.19
Module Abbreviations Seen on the
Outputs Spreadsheet
Module Type
Abbreviation
PPC-2030 Encoder Input Analog Output
EIAO
PPC-205x Analog Output
AO
There is only one parameter on the Outputs spreadsheet: Value.
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Value
This parameter displays the output value of the analog output
as a number between 0 and 32767. These numbers correspond
to the minimum and maximum output signal levels for the
selected Output Type. The analog signal range is determined by
the hardware, jumper configuration, and the setting of the
Output Type on the Channels spreadsheet for the channel with the
output selected as Heat/Cool Output Dest. The range may also be
scaled by the Output Scale Lo and Output Scale Hi settings
Range: 0 to 32767
NOTE!
The resolution of the analog outputs is 12 bits. The
output Value is displayed as a 15-bit integer. The
output Value must change by more than seven to
effect a measurable change in an analog output.
Soft Integer
The Soft Int spreadsheet lists the values of each of the 2100
software integer registers set aside in the PPC database for
exchanging data with the logic program.
Figure 3.25 Soft Int Spreadsheet
Select the Soft Int button to monitor or edit the software integer
values. Double click a field to change the setting.
The left column in the spreadsheet lists the name of the
register. The name contains the PPC number, the word and the
register offset (1-2100).
There is only one parameter on the Soft Int spreadsheet: Value.
Value
Software integer registers can be used to set or monitor values
in logic program variables that have been linked to the
corresponding database locations. The registers are all read/
write, but if a register is set as an output in the logic program,
the logic program updates its value and user entered values are
disregarded.
Range: -32768 to 32767
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Soft Boolean
The Soft Bool spreadsheet lists the values of each of the 1000
software Boolean registers set aside in the PPC database for
exchanging data with the logic program.
Figure 3.26 Soft BOOL Spreadsheet
Select the Soft Bool button to monitor or edit the software
Boolean values. Double click a field to change the setting.
The left column in the spreadsheet lists the name of the
register. The name contains the PPC number, the word and the
register offset (1-1000).
There is only one parameter on the Soft Bool spreadsheet: Value.
Value
Software Boolean registers can be used to set or monitor
internal coils in logic program that have been linked to the
corresponding register. The registers are all read/write, but if a
register is set as an output in the logic program, the logic
program updates its value and user entered values are
disregarded.
Range: False (0) or True (1)
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PPC Globals
Select PPC Globals from the View menu to display the screen in
Figure 3.27.
Figure 3.27 PPC Globals Screen
PPC Controller Select
Select the pertinent controller to display its parameters on this
screen.
Ambient Temperatures
The analog input modules measure the temperatures of each
terminal block on up to four AITBs in tenths of degrees F.
These give the cold junction compensation temperature for
each half of the terminal block. Note that the channel numbers
associated with a given cold junction reference depend on
whether the card is single-ended or differential. Table 2.13 on
page 48 correlates the terminals with the input number.
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System Status
Refer to Table 3.20 for a description of the system status
parameters.
Table 3.20
System Status
Parameter
Definition
Ambient Status
Ambient temperature error
Memory Status
RAM verification error
Loop Checksum
Closed-loop control program verified
HW Cfg Status
Hardware configuration error
Logic Run Status
Logic program is/is not running
Logic Load Status
Logic program is/is not loaded
Battery Status
Battery status
Logic Program Controls
Select Start or Stop to control the logic program.
Global Settings
Refer to Table 3.21 for a description of the global settings.
Time and Date
The PPC-2000’s clock calendar automatically updates the year,
month, date, hour, minute and second.
Table 3.21
Global Settings
Parameter
Doc.# 30002-00 Rev 2.3
Definition
Loop Start State
Determines whether closed-loop control channels are set to Off mode when the PPC is powered up or reset, or whether the control
channels resume operation in the same
control mode that was active before the PPC
was powered down.
Logic Start State
Determines whether or not the logic program, if
present, runs when the PPC is powered up or
reset
AC Frequency
Determines the input scan duration and DZC
output time base. Set this parameter equal to
the AC line frequency.
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Time and Date
The PPC-2000’s clock calendar automatically updates the year,
day of the week, month, date, hour, minute and second.
Program Version
The Program Version is an embedded program version label for
the firmware program. This selection is read-only. View the
program version by selecting About from the Help menu.
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4
Troubleshooting
This chapter describes troubleshooting methods and fault
indicators that may be useful if you experience difficulties with
your PPC-2000 system. Appropriate remedial procedures are
detailed below.
General Description
The following LEDs light for status or diagnostic purposes:
•
Green: Function operational, communications status (tx)
•
Red: Fault
•
Yellow: Communication status (rx)
•
Orange: Processor reset due to low power condition or
watchdog timeout
PPC-2010 Processor
The processor provides a System OK circuit for monitoring
program and microcontroller integrity. The output of the
watchdog timer is available through the 50 pin I/O header on
the processor board. This is an open collector type output (up to
100mA) and will sink current to common when the processor is
operating properly. An open circuit indicates a processor
failure and remains open until proper operation is established.
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Firmware Installation Procedures
Changing the firmware on the processor module involves minor
mechanical disassembly and reassembly of the controller.
Appropriate precautions should be taken to prevent
electrostatic discharge damage to the electronic components.
Wear a grounding strap and place components on static-free
grounded surfaces only.
A small flathead screwdriver is needed.
All control parameters will revert to factory defaults when
installing a new flash memory chip containing controller
firmware. Take a “snapshot” of the current configurations
using AnaWin3 before removing the flash memory chip.
The flash memory chip also stores the logic program if one has
been programmed. After replacing a flash memory chip, the
logic program should be downloaded to the controller using
LogicPro.
ç
CAUTION!
142
Be sure to take antistatic precautions.
1.
Save snapshot. The logic program will be erased.
2.
Power down the controller and system, including heaters
etc.
3.
Remove the power connection to the processor module and
any cables between the modules and terminal boards.
4.
Note and label cable locations.
5.
Remove the PPC-2000 system from the DIN rail or panel.
6.
Make sure the red top and bottom module latches on the
processor module are in the unlocked position (pushed
toward the back of the module.)
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Chapter 4: Troubleshooting
Back
Module
top
latch
(unlocked)
Module
top
latch
(locked)
Front
Figure 4.1
Assembled Modules Top View
Front
Module
bottom
latch
(locked)
Back
Figure 4.2
Doc.# 30002-00 Rev 2.3
Module
bottom
latch
(unlocked)
Assembled Modules Bottom View
7.
Gently rock and pull the modules apart.
8.
Refer to Figure 4.3 on page 144 to locate the flash memory
chip on the controller board. Use a PLCC extractor tool or
insert a small flat blade screwdriver into one of the
notches at the corner of the socket and gently pry the flash
memory chip out of the socket.
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9.
Insert the new flash memory chip into the socket as shown
in Figure 4.3, with the beveled edge and notched corner of
the flash memory chip facing the bottom edge of the
module. Be careful not to bend any legs while installing.
10. Reassemble the controller.
11. When the module is properly seated, close the two module
latches by pushing the latches toward the front of the
module. The two modules should be properly locked.
12. Replace the module on the DIN rail latch or screw the unit
back to the panel.
13. Reconnect cables.
14. Power the unit.
15. Download the Snapshot from AnaWin3 and reload the
logic program from LogicPro, if necessary.
Battery
Flash Memory
Chip (firmware)
Notch
JU2
B A
JU1
B A
Notch
Figure 4.3
144
PPC-2010 Internal View
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Chapter 4: Troubleshooting
Battery Installation Procedures
Changing the battery on the processor module involves minor
mechanical disassembly and reassembly of the controller.
Appropriate precautions should be taken to prevent
electrostatic discharge damage to the electronic components.
Wear a grounding strap and place components on static-free
grounded surfaces only.
A small flathead screwdriver is needed.
ç
CAUTION!
All control parameters and retained values in the
logic program will be lost when the battery is
removed! Take a Snapshot of the current
configurations in AnaWin3 before removing the
battery.
Be sure to take antistatic precautions.
1.
Power down the controller.
2.
Remove the power connection to the processor module and
any cables between the modules and terminal boards.
3.
Note and label cable locations.
4.
Remove the PPC-2000 system from the DIN rail or
panel.
5.
Make sure the red top and bottom module latches on the
processor module are in the unlocked position (pushed
toward the back of the module.)
Back
Module
top
latch
(unlocked)
Module
top
latch
(locked)
Front
Figure 4.4
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PPC Assembled Modules Top View
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Front
Module
bottom
latch
(locked)
Module
bottom
latch
(unlocked)
Back
Figure 4.5
PPC Assembled Modules Bottom
View
6.
Gently rock and pull the modules apart.
7.
Refer to Figure 4.3 on page 144 to locate the battery on the
controller board. Hold the controller board with the
battery side facing down a few inches above a table or
bench top. Pull up on the battery’s spring tab and allow the
battery to slip out of its housing and to the table top. Do
not use a metal object (screwdriver, etc.) to remove the
battery; this can short the + and – terminals. Replace
battery with Duracell DL2032 (3 volt) only; contact
Watlow Anafaze. Use of another battery may present a
risk of fire or explosion. See Battery Safety on page 11 for
safety instructions.
8.
Dispose of used battery promptly. Keep away from
children.
9.
Install the new battery.
10. Reassemble the controller.
11. When the module is properly seated, close the module
latches on the processor by pushing the latch toward the
front of the module. The two modules should be properly
locked.
12. Replace the module on the DIN rail or panel.
13. Reconnect cables.
14. Power the unit.
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15. Reset the controller and download the AnaWin3 Snapshot.
Refer to Resetting Closed-Loop Control Parameters on
page 156.
16. Reload logic program stored variables.
Processor Module LEDs
Refer to the following descriptions of LED indicators when
troubleshooting the Processor module.
•
Status Green LED On: Normal condition with logic
program stopped.
•
Status Green LED blinking four times per second,
on briefly (230 ms Off, 20 ms On): Normal condition
with logic program running.
•
Status LED Off: Indicates low power input.
Corrective Actions:
Check power connections.
Measure power output from power supply.
Disconnect I/O to check for excessive draw on power
supply.
•
Status Green LED blinking four times per second,
off briefly (50 ms Off, 200 ms On): Seen at the
beginning of logic program download while previous logic
program is being erased.
•
Error 1 Orange LED and Error 2 Red LED on:
Indicates watchdog timeout — control program no longer
running.
Corrective Actions:
Cycle power to PPC-2000 system. Perform RAM clear; see
Resetting Closed-Loop Control Parameters on page 156.
Replace Processor module.
•
Error 1 Orange LED on: Indicates low battery or low
voltage from the power supply.
Corrective Actions:
Check to make sure the voltage on the power supply is 12
to 28Vdc.
Replace the battery. See Battery Installation Procedures
on page 145.
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PPC-2021 - 2025 Analog Input
Refer to the following descriptions of LED indicators when
troubleshooting the analog input modules.
•
Error 3 Red LED blinking in sync with Green Status
LED: Indicates an open thermocouple.
Corrective Actions:
Verify that the correct sensor keys are installed correctly.
See Sensor Keys on page 46.
Check for an open thermocouple alarm and repair the corresponding thermocouple.
If the input is not used, make sure it is not selected as the
PV Source for any channel. Failed sensors are only reported for an input chosen as the PV Source for a channel.
•
Error 3 Red LED on or blinking but not in sync with
Green Status LED: Indicates common mode overvoltage.
The cause could be either a transitional noise source or a
steady state signal, such as an AC continuous source
electrically tied into an input line.
Corrective Actions:
Locate the source of the noise and remove it.
Remove ground loop problems.
Check cabling - loose cables or input wires may cause intermittent noise.
•
Error 4 Red LED on: Indicates a reference voltage
overload. The precision 10Vdc source is being overdrawn.
The LED will glow and increase with intensity as more
current is overdrawn.
Corrective Actions:
If an AITB is used with an analog input module, check to
make sure all key cards are inserted properly. Reverse insertion will cause the LED to light.
If the 10V reference on the AITBs are used to power an external circuit (i.e., bridges, etc.) make sure the total
current required does not exceed the specified limit. Refer
to Chapter 7, Specifications for current information. These
conditions will not harm the voltage source.
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•
Green Status and Error 3 LEDs remains on: Indicates
two or more modules are set to the same address.
Corrective Actions:
Change the rotary switch settings so that each module has
a unique address. Refer to Module Addresses on page 17.
•
Green Status LED remains off, on, or blinks
incorrectly: If analog input scanning is properly
functioning, the green LED blinks. If the LED remains off,
on, or blinks incorrectly, the module is not functioning.
Corrective Actions:
Make sure the rotary switch is set to the proper module address. Each module must have a unique address.
Cycle power to PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace module.
•
LED indicators are OK but inputs are not seen: Some
or none of the wired input data is being transferred to the
system. This may be an indication of a software or
hardware problem.
Corrective Actions:
Check all interconnects (terminal blocks and SCSI connector).
Check the input configuration in the AnaWin3 software.
Refer to Chapter 3, Software Setup for configuration information. Incorrect sensor type or wrong channel setup
could be seen as incorrect data retention.
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PPC-2030 Encoder In Analog Out
Refer to the following descriptions of LED indicators when
troubleshooting the encoder input analog output module.
•
Green Status LED remains off, on, or blinks
incorrectly: If counter input scanning is properly
functioning, the green LED blinks. If the LED remains off,
on, or blinks incorrectly, the module is not functioning.
Corrective Actions:
Make sure the rotary switch is set to the proper module address. Each module must have a unique address.
Cycle power to the PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace the module.
•
LED indicators are OK but pulse inputs are not seen
or are incorrect: Some or none of the wired input data is
being transferred to the system. This may be an indication
of a software or hardware problem.
Corrective Actions:
Ensure that inputs are wired to the correct pins on the
high density cable connector or EITB.
Check that the cable is connected to the correct port. The
connector closest to the back carries pulse inputs 1 and 2.
The connector closer to the face of the module carries pulse
inputs 3 and 4.
Make sure that the module has been configured properly
for quadrature vs. single phase pulse inputs for each
channel used. A quadrature encoder connected to an input
configured as a single-phase will appear to operate backwards. Rotation that should increase the count decreases
it, and vice versa. Refer to Figure 2.5 on page 20 for instructions on setting switches for the encoder inputs.
•
LED indicators are OK but analog outputs are not
seen or are incorrect: Some or none of the wired input
data is being transferred to the system. This may be an
indication of a software or hardware problem.
Corrective Actions:
Ensure connections to terminal blocks are correct. Refer to
Analog Output Connections on page 60 for analog output
wiring.
Be sure the software configuration matches the hardware
setup.
Check that the jumpers are set correctly. See PPC-2030
Jumper Settings on page 20.
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Chapter 4: Troubleshooting
PPC-2040 Digital I/O
Refer to the following descriptions of LED indicators when
troubleshooting the digital I/O module.
•
Green Status LED remains off, on, or blinks
incorrectly: When the module is correctly functioning the
green LED blinks. If the LED remains off, on, or blinks
incorrectly, the module may not be functioning correctly.
Corrective Actions:
Make sure the rotary switch is set to the proper module address. Each module must have a unique address.
Cycle power to PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace the module.
•
Green Status LED is blinking but inputs and/or
outputs are not reading correctly:
Corrective Actions:
Check to make sure the I/O wiring is correct. See Connecting I/O to the PPC-2040 on page 61.
•
Red Error LED remains on: Indicates at least one
digital output is in an incorrect state. The cause could be
an overloaded output or a failed output driver.
Corrective Actions:
Check the output circuits for shorts and repair if necessary.
Check the load on the outputs to make sure that none of
them exceeds 150mA.
Check to make sure the I/O wiring is correct. See Connecting I/O to the PPC-2040 on page 61.
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PPC-2050 Analog Out
Refer to the following descriptions of LED indicators when
troubleshooting the analog output module.
•
Green Status LED remains off, on, or blinks
incorrectly: When the module is correctly functioning the
green LED blinks. If the LED remains off, on, or blinks
incorrectly, the module may not be functioning correctly.
Corrective Actions:
Make sure the rotary switch is set to the proper module
address. Each module must have a unique address.
Cycle power to PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace the module.
•
Green Status LED is blinking but outputs are not
functioning correctly:
Corrective Actions:
Check to make sure the I/O wiring is correct. See Connecting Analog Outputs to the PPC-205x on page 67.
Check that the jumpers are set correctly. See
PPC-205x Jumper Settings on page 22.
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Chapter 4: Troubleshooting
PPC-206x Digital Out
Refer to the following descriptions of LED indicators when
troubleshooting the digital output module.
•
Green Status LED remains off, on, or blinks
incorrectly: When the module is correctly functioning the
green LED blinks. If the LED remains off, on, or blinks
incorrectly, the module may not be functioning correctly.
Corrective Actions:
Make sure the rotary switch is set to the proper module address. Each module must have a unique address.
Cycle power to PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace the module.
•
Green Status LED is blinking but outputs are not
functioning correctly:
Corrective Actions:
Check to make sure the I/O wiring is correct. See Connecting to the Relay Outputs on the PPC-206x on page 70.
Check to make sure the digital outputs are correctly configured. See Digital Inputs and Outputs on page 154.
PPC-207x Digital In
Refer to the following descriptions of LED indicators when
troubleshooting the digital input module.
•
Green Status LED remains off, on, or blinks
incorrectly: When the module is correctly functioning the
green LED blinks. If the LED remains off, on, or blinks
incorrectly, the module may not be functioning correctly.
Corrective Actions:
Make sure the rotary switch is set to the proper module address. Each module must have a unique address.
Cycle power to PPC-2000 system.
Check that the modules are connected properly; refer to
Module Assembly on page 24.
Perform a RAM clear; refer to Resetting Closed-Loop
Control Parameters on page 156.
Replace the module.
•
Green Status LED is blinking but inputs are not
working correctly:
Corrective Actions:
Check to make sure the I/O wiring is correct. See Connecting Digital Inputs to the PPC-207x on page 74.
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Troubleshooting and Corrective Actions
If the system fails to perform as expected, it may be necessary
to perform one or more of the following procedures to discover
the cause and restore normal operation.
Digital Inputs and Outputs
If a digital input or output doesn’t seem to be working, check
the following:
•
Is the digital I/O point’s Direction set correctly as an input
or output? See Digital I/O on page 132.
•
Is the Logic set correctly? Refer to Digital I/O on page 132.
•
Is the output selected as an Output Destination for more
than one function (e.g. a control output and an alarm
output)? See Channels on page 115 and Alarms on page
123.
•
Is the digital I/O point associated with a variable set as an
output in a logic program? Refer to the LogicPro User’s
Guide.
•
Are the cable and wiring connections correct? See
Connecting I/O to the PPC-2010 on page 37, Connecting to
the Relay Outputs on the PPC-206x on page 70, and
Connecting Digital Inputs to the PPC-207x on page 74.
•
Is leakage current from one of the configurable I/O points
such that a device is being switched on or partly on? See
Connecting Digital Outputs on page 41.
•
Is the field I/O device powered? Note digital outputs on the
PPC-2010 and PPC-2040 sink current. That current must
be sourced by an external device that is referenced to the
PPC’s common. See Connecting Digital Outputs on page 41
for the PPC-2010 and Connecting Digital Outputs on page
65 for the PPC-2040.
Process Variable
If the Process Variable is not updating, check the following:
154
•
Is a valid analog input selected as the PV Source? See
Channels on page 115.
•
Is the input corresponding to the PV Source updating as
expected? If not check LEDs on the associated module, See
corresponding module section in this chapter.
•
Is the input wiring correct? See Connecting I/O to the
PPC-2010 on page 37, Connecting Analog Inputs to the
PPC-2021 — 2025 on page 45, Connecting Encoders and
Analog Outputs to the PPC-2030 on page 55, or Connecting
to the Relay Outputs on the PPC-206x on page 70.
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Chapter 4: Troubleshooting
Communications
If communications has never worked, check the following:
•
Is the PPC-2010 Processor running? The RX LED on the
port lights as the controller receives signals. The TX LED
lights if the controller receives a valid Modbus request.
This indicates a response being sent by the PPC.
•
Is the communications cable in the correct connector on
the PPC-2010?
•
Is the other wiring correct? See Connecting
Communication Ports on page 78.
•
Is the RS-232/485 converter configured and working
properly? See Connecting Communication Ports on page
78 and the converter documentation.
•
Are the communications parameters set the same in both
the PPC-2000 and the host device or software? See
Modbus Network Address on page 86.
•
Is the host device or software configured properly? See the
appropriate user documentation.
•
Is the correct communications port selected? See the
appropriate user documentation.
If communications was working and has failed, check these
things:
•
Is the PPC-2010 Processor running? The RX LED on the
port lights as the controller receives signals. The TX LED
lights if the controller receives a valid Modbus request.
This indicates a response being sent by the PPC.
•
Has the rotary switch setting on the Processor Module
been changed? See Modbus Network Address on page 86.
•
Is the wiring correct? See Connecting Communication
Ports on page 78.
•
Have any of the communications port settings on the
computer been changed? See the appropriate user
documentation.
•
Is the RS-232/485 converter working properly?
If one of the programmable communications parameters may
have changed, establishing communications by following these
steps will demonstrate that all the components are functioning
and connections are correct:
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ç
CAUTION!
Do not perform this procedure at a time during which
closed-loop control and logic program outputs
should not be turned off.
1.
Remove power from the PPC-2000 system.
2.
Set the rotary switch on the Processor module to position
H.
3.
Power up the PPC-2000 system.
4.
Set the communications parameters used by the host
device or software to the appropriate values for setting H:
Network address: 1
Baud rate: 19.2 kbaud
Parity: Even
Data bits: 8
Stop bits: 1
5.
Attempt to communicate.
If the PPC-2000 still will not communicate and all other components and settings have been verified, contact technical
support at the number in the front of this manual.
Resetting Closed-Loop Control Parameters
To restore all the closed-loop control, alarm, global and I/O
parameters to their factory default settings, perform the following procedure:
NOTE!
This procedure erases ALL user settings including
I/O assignments and restores all parameters to the
factory defaults, and all retained logic program values
are reset. Make a record of all settings you may wish
to restore before performing this procedure. A
Snapshot may be made in AnaWin3 to record closedloop control parameters for future downloading.
This procedure resets the programmable
communications parameters and restores them to the
factory defaults. Make a record of all settings you may
wish to restore before performing this procedure.
After performing the following procedure, refer to Setting
Programmable Modbus Addresses on page 87, if necessary, to
reprogram the Modbus address or baud rate.
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Chapter 4: Troubleshooting
ç
CAUTION!
Do not perform this procedure at a time during which
closed-loop control and logic program outputs
should not be turned off.
1.
Remove power from the PPC-2000 system.
2.
Note the setting of the rotary switch on the Processor
Module.
3.
Set the rotary switch to position E.
4.
Power up the PPC-2000 system.
5.
Wait five seconds.
6.
Remove power from the PPC-2000 system.
7.
Set the rotary switch back to the position noted in Step 2.
8.
Power up the PPC-2000 system.
Disabling Control
If the settings in a PPC are not known it may be desirable to
power up the system in a state that will not generate outputs.
The following procedure describes how to power up the PPC2000 such that the closed-loop control and logic program, if any,
do not automatically begin:
ç
CAUTION!
Doc.# 30002-00 Rev 2.3
Do not perform this procedure at a time during which
closed-loop control and logic program outputs
should not be turned off.
1.
Remove power from the PPC-2000 system.
2.
Note the setting of the rotary switch on the Processor
Module.
3.
Set the rotary switch to position H.
4.
Power up the PPC-2000 system.
5.
Set channels to the desired control modes to begin closedloop control.
6.
Click the Start Logic button on the PPC Globals screen to
start the logic program, if desired.
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5
LogicPro and Modbus Reference
Overview
This chapter is designed for engineers and technicians tasked
with setting up third-party software or an operator interface
terminal for operating and monitoring of a PPC System. The
parameter addressing described in this chapter applies to
firmware versions 2.0 (released 9/1/99) and later. This chapter
provides information needed to address parameters when
writing programs using LogicPro. For instructions on
operating the Watlow Anafaze software, AnaWin3, with your
PPC system, refer to Chapter 3, Software Setup.
Text Conventions in the Database Sections
Table 5.1 shows the parameter names and abbreviations as
seen in AnaWin3. Parameter names are shown as a reference
only for programming purposes.
Table 5.1
Doc.# 30002-00 Rev 2.3
Parameter Names & Abbreviations
Abbreviation
Parameter
SP
Setpoint
PV
Process Variable
HP
High Process
LP
Low Process
HD
High Deviation
LD
Low Deviation
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A special font or typeface is used to indicate parameter names
and text seen in the AnaWin3 screens.
Process Variable Low (PV Lo)
Set this parameter to the value displayed when the signal
is at the level set in Input Signal Low (Input Signal Lo).
Figure 5.1
Sample Text
The words Process Variable Low and Input Signal Low represent
parameter names. The words (PV Lo) and (Input Signal Lo) are the
abbreviated terms seen in AnaWin3. These abbreviations are
shown for reference in this chapter only when the AnaWin3
name differs from the listed parameter names.
The PPC-2000 Database
The PPC stores setpoints and other control parameters along
with process variable values and digital I/O states in its
database. The database is analogous to a set of tables.
Parameters form the columns of the tables. AnaWin3, thirdparty HMI software, operator interface terminals and LogicPro
programs access these process parameters and data in the
database.
Think of the database as a series of tables. Each table holds the
values of a different set of parameters: analog inputs; channels;
digital I/O; analog outputs; soft integers; soft booleans; and
globals. In each table the columns represent parameters and
the rows represent analog inputs, or channels, or digital I/O
and so on.
For example, in the analog input table, the columns represent
the analog input parameters such as Input Value, Input Type, and
Input Filter. Each row holds the settings of each of these
parameters for a particular analog input.
Table 5.2
Example Database Table
Input Value Input Type
Input 1
2089
44
2089
Input 2
44
2089
44
Input 3
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Input Filter
3
3
3
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Chapter 5: LogicPro and Modbus Reference
The cells in the database tables are referred to as registers.
There are two types of registers in the database: bit registers
and word registers. Bit registers hold a single bit and word
registers hold 16-bit integers.
These registers may be accessed by software running on a PC
or by an operator interface terminal or by a logic program
running on the PPC itself. Some parameters are read only, but
others may be read or changed.
Data Table Organization
The datatable is organized according to the Modbus standard
for PLC memory. Memory is divided into four sections by size
and function. The Modbus specification allows for up to 9,999
registers for each section. Some registers are not available in
the PPC-2000. Consult the parameter tables in this chapter to
determine which registers are available. Also, the usage of
some registers in the PPC-2000 differs from standard PLC
usage; for instance, coils are used for digital input status.
Coils
Coils are bit registers. Each have a value of 1 or 0. Software
interfaces may read or write the values stored in these
registers. The modbus addresses for Coils range from 0001 to
9999 (decimal).
Inputs
Inputs are bit registers. Each has a value of 1 or 0. Software
interfaces may read but not write the values stored in these
registers. The modbus addresses for Inputs range from 10001
to 19999 (decimal).
Holding Registers
Holding registers are 16-bit size; they store values from
-32,768 to 32,767. Software interfaces may read or write the
values stored in these registers. Some of the PPC-2000
parameters stored in holding registers have more limited
ranges than the register size. The modbus addresses for
holding registers range from 40001 to 49999
Input Registers
Input registers are 16-bit in size; they store values from
-32,768 to 32,767. Software interfaces may read but not write
the values stored in these registers. The PPC-2000 uses these
registers to store analog and encoder input values. The Modbus
addresses for the input registers range from 30001 to 39999.
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Accessing the Database with Modbus
Each register can be individually accessed using software and
the Modbus communications protocol via a serial port on the
processor module because each register has a unique Modbus
address. The Modbus address for each parameter is given in
sections Analog and Counter Input Parameters in the Database
on page 163 through Global Parameters in the Database on
page 206.
Because the database is quite large, it is impractical and
undesirable to list each Modbus address. Instead, the first and
last addresses for each parameter are listed. Individual
registers are addressed by determining the offset from the first
address corresponding to the particular input, output, or
channel.
For example, in a PPC-2000 system with 32 analog inputs on
one module, the register addresses for inputs 1-32 are 30601 to
30632. The measured value corresponding to the first analog
input is stored at address 33601. The value of the second input
is stored at address 33602. The value of input 26 is stored at
address 30626, and so on. The Database Offset for the first
analog input is said to be 1, for the second input is 2, and for the
26th input is 26. In each section describing a database table,
the Database Offset scheme is explained.
How LogicPro Accesses the Database
Logic programs can be written and downloaded using LogicPro.
Typically, such programs access digital and/or analog
I/O and may also access other values stored in the database.
Because the user-written logic program resides in the processor
module, it does not use the serial port or Modbus to access the
database. Instead, each register can be accessed by logic
program variables using one of the I/O drivers supplied with
LogicPro.
Some drivers correspond to modules. These drivers are used to
access the digital and analog I/O values corresponding to the
field devices connected to each module. The LogicPro
IO Physical Address is used in conjunction with these
module-specific drivers to use a digital or analog I/O value in a
logic program.
For example, the value measured by a thermocouple attached
to the first input on an Analog In module with address 2 is
accessed with the Analog_In_202x driver and the Logic Pro IO
Physical Address 2.1.
The LogicPro Database driver facilitates access to all database
parameters. Because the database is large, it impractical and
undesirable to list each LogicPro address. Instead, the
parameter number and database offset range for each
parameter are supplied. Individual registers are addressed by
coupling the parameter number and the database offset
corresponding to the particular input, output, or channel.
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For example, the parameter number for setpoint, found in
Table 5.12 on page 174, is 95. The database offset for channel
parameters is channel number. So using the Database IO
Driver supplied with LogicPro the IO Physical Address for the
setpoint of channel 23 is 95.23.
Refer to the LogicPro User’s Guide for detailed instructions on
using the IO Drivers and creating logic programs. Refer to this
chapter of this manual for specific LogicPro IO Physical
Addresses, and parameter numbers.
Analog and Counter Input Parameters in the
Database
Analog input parameters determine how measurements of
signals from sensors attached to modules are read and scaled
into engineering units for use by closed-loop control channels,
monitor channels and logic programs. These parameters can be
read and set by Modbus devices and logic programs.
Accessing Analog and Counter Input Parameters with
Modbus
To access analog and counter input parameters, use the
database offset as the Modbus address offset. See Table 5.3 on
page 164 through Table 5.6 on page 166 for a list of the
database offsets and Modbus addresses corresponding to the
analog and counter inputs.
Table 5.8 on page 168 lists first and last Modbus addresses for
each input parameter. Use these addresses when accessing
analog or counter input parameters with third-party software
or operator interface terminals.
Accessing Analog and Counter Input Parameters with
LogicPro
To access counts, frequencies, and analog input values
measured by the modules, use the appropriate IO Driver in
LogicPro. There are separate drivers for each type of module.
The driver requires an IO Physical Address to determine which
analog input to read on the module. See Table 5.3 on page 164
through Table 5.6 on page 166 to determine LogicPro IO
Physical Address.
The LogicPro IO Physical Addresses are listed by input
according to the default Input names as seen in AnaWin3. To
correlate the AnaWin3 name with the hardware connection see
Table 2.10 on page 39, Table 2.12 on page 47, Table 2.15 on
page 56, Table 2.16 on page 56, and Table 2.19 on page 60.
When a logic program variable accesses an analog input
parameter, the parameter number (#) and the Database Offset
are used in conjunction with LogicPro’s Database IO Driver.
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The IO Physical Address is constructed from the parameter
number and the database offset.
See the LogicPro User’s Guide for specific instructions on
addressing analog and encoder input parameters.
See Table 5.3 below through Table 5.6 on page 166 for a list of
the database offsets for each analog and counter input. See
Table 5.8 on page 168 for analog input parameter numbers.
Analog Input Numbers and Address Offsets
Table 5.3 below through Table 5.6 on page 166 list the LogicPro
IO Physical Addresses, Database Offsets and sample Modbus
addresses corresponding to each analog and counter input. The
sample Modbus addresses are for the Input Value.
Table 5.3
AnaWin3 Name1
(Input Spreadsheet)
Addresses for Analog Inputs on the
PPC-202x Modules
LogicPro I/O Physical Address
Modbus Addressing
Analog_In_202x
IO Driver2
Database
IO Driver3
Database
Offset
Sample
Address
PPC1:AI 1.1
1.1
#.1
1
30801
PPC1:AI 1.2
1.2
#.2
2
30802
…
…
…
…
…
PPC1:AI 1.32
1.32
#.32
32
30832
PPC1:AI 2.1
2.1
#.33
33
30833
PPC1:AI 2.2
2.2
#.34
34
30834
…
…
…
…
…
PPC1:AI 2.32
2.32
#.64
64
30864
PPC1:AI 3.1
3.1
#.65
65
30865
PPC1:AI 3.2
3.2
#.66
66
30866
…
…
…
…
…
PPC1:AI 3.32
3.32
#.96
96
30896
PPC1:AI 4.1
4.1
#.97
97
30897
PPC1:AI 4.2
4.2
#.98
98
30898
…
…
…
…
…
PPC1:AI 4.32
4.32
#.128
128
30928
1The AnaWin3 names are shown for the first PPC-2000 in the system.
See Inputs on page 127
for a full explanation of analog input naming.
2Use this address with the Analog_In_202x IO Driver when addressing Input Value.
3Use this address with the Database IO Driver when addressing input parameters other than
Input Value. Replace the # with the parameter number (#) from Table 5.8 on page 168 for the
parameter you want to address.
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Table 5.4
AnaWin3 Name1
(Input Spreadsheet)
Addresses for Encoder Inputs on the
PPC-2030 Encoder In Analog Out
Module
LogicPro I/O Physical Address
Modbus Addressing
Encoder_Analog_
2030 IO Driver2
Database
IO Driver3
Database
Offset
Sample
Address
PPC1:EIAO 11.1.1 C
11.1.1
#.129
129
30929
PPC1:EIAO 11.2.1 F
11.2.1
#.130
130
30930
PPC1:EIAO 11.1.2 C
11.1.2
#.131
131
30931
PPC1:EIAO 11.2.2 F
11.2.2
#.132
132
30932
PPC1:EIAO 11.1.3 C
11.1.3
#.133
133
30933
PPC1:EIAO 11.2.3 F
11.2.3
#.134
134
30934
PPC1:EIAO 11.1.4 C
11.1.4
#.135
135
30935
PPC1:EIAO 11.2.4 F
11.2.4
#.136
136
30936
PPC1:EIAO 12.1.1 C
12.1.1
#.137
137
30937
PPC1:EIAO 12.2.1 F
12.2.1
#.138
138
30938
PPC1:EIAO 12.1.2 C
12.1.2
#.139
139
30939
PPC1:EIAO 12.2.2 F
12.2.2
#.140
140
30940
PPC1:EIAO 12.1.3 C
12.1.3
#.141
141
30941
PPC1:EIAO 12.2.3 F
12.2.3
#.142
142
30942
PPC1:EIAO 12.1.4 C
12.1.4
#.143
143
30943
PPC1:EIAO 12.2.4 F
12.2.4
#.144
144
30944
PPC1:EIAO 13.1.1 C
13.1.1
#.145
145
30945
PPC1:EIAO 13.2.1 F
13.2.1
#.146
146
30946
PPC1:EIAO 13.1.2 C
13.1.2
#.147
147
30947
PPC1:EIAO 13.2.2 F
13.2.2
#.148
148
30948
PPC1:EIAO 13.1.3 C
13.1.3
#.149
149
30949
PPC1:EIAO 13.2.3 F
13.2.3
#.150
150
30950
PPC1:EIAO 13.1.4 C
13.1.4
#.151
151
30951
PPC1:EIAO 13.2.4 F
13.2.4
#.152
152
30952
PPC1:EIAO 14.1.1 C
14.1.1
#.153
153
30953
PPC1:EIAO 14.2.1 F
14.2.1
#.154
154
30954
PPC1:EIAO 14.1.2 C
14.1.2
#.155
155
30955
PPC1:EIAO 14.2.2 F
14.2.2
#.156
156
30956
PPC1:EIAO 14.1.3 C
14.1.3
#.157
157
30957
PPC1:EIAO 14.2.3 F
14.2.3
#.158
158
30958
PPC1:EIAO 14.1.4 C
14.1.4
#.159
159
30959
PPC1:EIAO 14.2.4 F
14.2.4
#.160
160
30960
1The AnaWin3 names are shown for the first PPC-2000 in the system.
See Inputs on page 127
for a full explanation of analog input naming. C=Counter input, F=Frequency input.
2Use this address with the Encoder_Analog_2030 IO Driver when addressing Input Value.
3Use this address with the Database IO Driver when addressing input parameters other than
Input Value. Replace the # with the parameter number (#) from Table 5.8 on page 168 for the
parameter you want to address.
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Table 5.5
Name1
AnaWin3
(Input Spreadsheet)
Addresses for Counter Inputs on the
PPC-2010 Processor Module
LogicPro I/O Physical Address2
Modbus Addressing
Processor_2010
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:Proc 0.1.1 C
0.1.1
#.161
161
30961
PPC1:Proc 0.2.1 F
0.2.1
#.162
162
30962
1The AnaWin3 names are shown for the first PPC-2000 in the system.
See Inputs on page 127
for a full explanation of analog input naming. C=Counter input, F=Frequency input.
2LogicPro Variable Type must be INT and IO Size must be WORD.
3Use this address with the Processor_2010 IO Driver when addressing the count or frequency
Input Value.
4Use this address with the Database IO Driver when addressing input parameters other than
Input Value. Replace the # with the parameter number (#) from Table 5.8 on page 168 for the
parameter you want to address.
Soft inputs are used when the Process Variable Source of a
channel must be a register to which a logic program can write.
Channel Output registers are used as the Setpoint Source for the
secondary cascade channel.
Table 5.6
Name1
AnaWin3
(Input Spreadsheet)
Addresses for Soft Inputs and
Channel Outputs
LogicPro I/O Physical Address2
Modbus Addressing
Soft_Input
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:Soft Input 1
1
#.165
165
30965
PPC1:Soft Input 2
2
#.166
166
30966
…
…
…
…
…
PPC1:Soft Input 48
48
#.212
212
31012
PPC1:Channel 1 Output
#.215
215
31015
PPC1:Channel 2 Output
#.216
216
31016
…
…
PPC1:Channel 48 Output
…
…
n/a
#.262
262
31062
1The AnaWin3 names are shown for the first PPC-2000 in the system. See Inputs on page 127
for a full explanation of analog input naming.
Variable Type must be INT and IO Size must be WORD.
3Use this address with the Soft_Input IO Driver when addressing the Input Value of a Soft Input.
4Use this address with the Database IO Driver when addressing other input parameters. Replace the # with the parameter number (#) from Table 5.8 on page 168 for the parameter you
want to address.
2LogicPro
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Chapter 5: LogicPro and Modbus Reference
Table 5.7
AnaWin3 Name1
(Input Spreadsheet)
Addresses for Encoder Inputs on the
PPC-2040 Digital I/O Modules
LogicPro I/O
Physical Address2
Modbus Addressing
Digital_IO_2040
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:DIO 21.1.1 C
21.1.1
#.301
301
31101
PPC1:DIO 21.2.1 F
21.2.1
#.302
302
31102
PPC1:DIO 21.1.2 C
21.1.2
#.303
303
31103
PPC1:DIO 21.2.2 F
21.2.2
#.304
304
31104
PPC1:DIO 22.1.1 C
22.1.1
#.305
305
31105
PPC1:DIO 22.2.1 F
22.2.1
#.306
306
31106
PPC1:DIO 22.1.2 C
22.1.2
#.307
307
31107
PPC1:DIO 22.2.2 F
22.2.2
#.308
308
31108
PPC1:DIO 23.1.1 C
23.1.1
#.309
309
31109
PPC1:DIO 23.2.1 F
23.2.1
#.310
310
31110
PPC1:DIO 23.1.2 C
23.1.2
#.311
311
31111
PPC1:DIO 23.2.2 F
23.2.2
#.312
312
31112
PPC1:DIO 24.1.1 C
24.1.1
#.313
313
31113
PPC1:DIO 24.2.1 F
24.2.1
#.314
314
31114
PPC1:DIO 24.1.2 C
24.1.2
#.315
315
31115
PPC1:DIO 24.2.2 F
24.2.2
#.316
316
31116
PPC1:DIO 25.1.1 C
25.1.1
#.317
317
31117
PPC1:DIO 25.2.1 F
25.2.1
#.318
318
31118
PPC1:DIO 25.1.2 C
25.1.2
#.319
319
31119
PPC1:DIO 25.2.2 F
25.2.2
#.320
320
31120
PPC1:DIO 26.1.1 C
26.1.1
#.321
321
31121
PPC1:DIO 26.2.1 F
26.2.1
#.322
322
31122
PPC1:DIO 26.1.2 C
26.1.2
#.323
323
31123
PPC1:DIO 26.2.2 F
26.2.2
#.324
324
31124
1The AnaWin3 names are shown for the first PPC-2000 in the system. See Inputs on page 127
for a full explanation of analog input naming. C=Counter input, F=Frequency input.
Variable Type must be INT and IO Size must be WORD.
3Use this address with the Digital_IO_2040 IO Driver when addressing the count or frequency
Input Value.
4Use this address with the Database IO Driver when addressing input parameters other than
Input Value. Replace the # with the parameter number (#) from Table 5.8 on page 168 for the
parameter you want to address.
2LogicPro
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Analog and Encoder Input Parameters
Table 5.8 lists the parameter number (#), range, and first and
last Modbus addresses for each analog input parameter. These
values are used when accessing analog input parameters with
third-party software, operator interface terminals or LogicPro
programs.
The range of some of the parameters depends on which input
type is selected. See Table 5.10 on page 170 for a list of the
input types and their corresponding ranges. While all the input
parameter values are 16-bit integers, many, such as Input Type,
are numerical representations of settings that have special
meanings to the controller. See the tables under the
corresponding parameter descriptions for explanations of the
possible settings.
Note that while any analog input can be assigned to any control
channel, the channel number that an input is assigned to has
no effect on the input variable’s data table address.
Table 5.8
Parameter
168
Input Parameters
Modbus
Address
Hex
Address
#
Range
Sample Time
74
200-700 ms
typical
31801-32200
708-897
Input,
Raw Counts
72
0-65535
31201-31600
4B0-63F
Input Value
67
30801-31200
320-4AF
Input Status
75
0-16
32201-32600
898-A27
See Table 5.9
Input Type
60
0-60
41751-42150
6D6-865
See Table 5.9
Input Filter
61
0-255
42151-42550
866-9F5
Temperature
Scale
64
0-1
42951-43350
B86-D15
See Table 5.11
Input Signal Low
71
-32768 to
+32767
44551-44950
11C6-1355
See Table 5.11
Input Signal High
70
-32768 to
+32767
44151-44550
1036-11C5
See Table 5.11
Process
Variable Low
69
-32768 to
+32767
43751-44150
EA6-1035
Process
Variable High
68
-32768 to
+32767
43351-43750
D16-EA5
PV Offset/
Counter Reset
78
-32768 to
+32767
44951-45350
1356-14E5
-32768 to
+32767
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Notes
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 5: LogicPro and Modbus Reference
Sample Time
Time, in milliseconds, between scans for this input, as last
reported by the analog input driver. This is a read-only
parameter.
Input, Raw Counts
Actual raw counts read during the last scan for analog and
counter inputs.
Input Value
Fully linearized and filtered input reading in engineering
units: degrees for temperature inputs or specified engineering
units for linear inputs. Input values are copied to the process
variable register for channels with this input chosen as the
Process Variable Source. Units depend on Input Type.
Input Status
This read-only register contains information about the sensor.
Table 5.9 lists and describes the possible values for the
parameter.
Table 5.9
Input Status
Value
Input Status
0
No problems
1
Open sensor
2
Shorted RTD sensor
8
Common mode overvoltage. There is too much noise on
the sensor to make an accurate reading.
16
Ambient temperature error. Temperature is outside controller's operating range.
Input Type
Specify the sensor type. Table 5.10 on page 170 shows the
default sensor ranges for the various inputs. All Input Value
registers store integers. In order to provide the desired
precision for many Input Types, the integer stored in the register
may be in tenths of a degree or hundredths of a millivolt. For
example, if an input is set to input type 6 and the Input Value
register contains a value of 2506, the actual measure value is
25.06mV because the values in the register are in units of
hundredths of a millivolt.
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Table 5.10
Value
0
1
2
3
4
5
6
7
8-9
10
11
12
13
14
15
16
17-19
20
21
22
23
24
25-39
31
40
41
42
43
44
45
46
47
48
49
50
51
52-57
58
59
60
61
170
Input Types
AnaWin3 Name
(No Input)
Volts: -1 to 10Vdc
Volts: -0.5 to 5Vdc
Volts: -0.1 to 1Vdc
Spare
Volts: -50 to 500mVdc
Volts: -10 to 100mVdc
Volts: -5 to 50mVdc
Spare
Linear -1 to 10 (V)
Linear -0.1 to 1 (V)
Linear -10 to 100 (mV)
Linear -2 to 20 (mA)
Linear (Counts)
Linear 0 to 10k (Hz)
Linear 0 to 300 (Hz)
Spare
Current: 0-20mA
Current: 4-20mA
Spare
Counter
Frequency
Spare
100K ohm Thermistor
B T/C (1°F)
C T/C (1°F)
D T/C (1°F)
E T/C (0.1°F)
J T/C (0.1°F)
K T/C (0.1°F)
N T/C (0.1°F)
R T/C (0.1°F)
S T/C (0.1°F)
T T/C (0.1°F)
F T/C (Platinel2)
G T/C (1°F)
Spare
J T/C without open detection
K T/C without open detection
RTD, 100 Ohm Plat
RTD, 100 Ohm Plat High
Watlow Anafaze
Range
Units
N/A
N/A
-1000 to 10000
mV
-500 to 5000
mV
-1000 to 10000
0.1mV
N/A
N/A
-500 to 5000
0.1mV
-1000 to 10000
0.01mV
-500 to 5000
0.01mV
N/A
N/A
-1000 to 10000
mV
-1000 to 10000
0.1mV
-1000 to 10000
0.01mV
-2000 to 20000
0.01mA
-32767 to 32768
Counts
-32767 to 32768
Hz
-32767 to 32768
0.01Hz
N/A
N/A
0 to 20000
0.1mA
40 to 20000
0.1mA
N/A
N/A
-32767 to 32768
counts
-10000 to 10000
Hz
N/A
N/A
-2500 to 32760°F
0.01°F
32 to 3308
1°F
32 to 4200
1°F
32 to 4200
1°F
-4540 to 12210
0.1°F
-3460 to 15980
0.1°F
-4540 to 22490
0.1°F
-4540 to 23720
0.1°F
-580 to 32150
0.1°F
-580 to 32150
0.1°F
-4540 to 7520
0.1°F
320 to 22500
0.1°F
32 to 4200
1°F
N/A
N/A
-3460 to 15980
0.1°F
-4540 to 22490
0.1°F
-4180 to 5210
0.1°F
-4180 to 15620
0.1°F
Doc.# 30002-00 Rev 2.3
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Chapter 5: LogicPro and Modbus Reference
NOTE!
The counter and frequency inputs update four times
per second (4Hz), except the Linear 0 to 300 (Hz) input
type, which updates once every 25 seconds (.04Hz).
The update rate of all other input types depends on
the module. See Chapter 7, Specifications.
Input Filter
This parameter determines the time constant for the filter
applied during the conversion of Input, Raw Counts to Input Value.
The input value responds to a step change by going to
approximately 2/3 of its final value, within the number of scans
set here. A larger number yields a slower, or more damped,
response to changes as measured by the sensor.
Temperature Scale
This register sets the units used during the conversion of Input,
Raw Counts to Input Value. This parameter applies only to
temperature sensor input types. Table 5.11 lists and describes
the possible settings.
Table 5.11
Temperature Scale Conversion
Value
Temperature Scale
0
degrees F
1
degrees C
Input Signal Low (Input Signal Lo)
This is the input signal level that corresponds to the low
process value set in Process Variable Low (see below). For custom
linear inputs, this parameter is the lowest level signal the
sensor or encoder will supply. Typically, this corresponds to the
lowest process variable to be measured. The units and range for
this parameter correlate to the selected Input Type. See Table
5.10 on page 170. See Setting Input Signal Lo and Input Signal
Hi on page 99 for detailed information.
Input Signal High (Input Signal Hi)
This is the input signal level that corresponds to the high
process value set in Process Variable High (see below). For custom
linear inputs, this parameter is the highest level signal the
sensor or encoder will supply. Typically, this corresponds to the
highest process variable to be measured. The units and range
for this parameter correlate to the selected Input Type. See Table
5.9. See Setting Input Signal Lo and Input Signal Hi on page
99 for detailed information.
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Process Variable Low (PV Lo)
Set this register to the value to be displayed when the signal is
at the level set in Input Signal Low (see above). See Setting PV Lo
and PV Hi on page 99 for detailed information.
Process Variable High (PV Hi)
Set this register to the value to be displayed when the signal is
at the level set in Input Signal High (see above). See Setting PV Lo
and PV Hi on page 99 for detailed information.
PV Offset/Counter Reset
This value is added to the scaled input before it is entered in the
Input Value register for temperature sensor input types
(T/Cs and RTDs). For counter input types, when this register is
written to, the count is set equal to the value written. This can
be used to reset or pre-load counter values.
Channel Parameters in the Database
Channel parameters determine the behavior of the PPC’s 48
closed-loop control channels. Channels are not inherently
associated with any particular hardware I/O. The user
associates a channel with a particular input and output by
setting the Process Variable Source and the Output Destination
parameters.
Channel numbers are, therefore, selected at the users
discretion. Each channel does, however, have many parameters
associated with it. It is up to the user to make sure the channel
parameters are appropriate for closed-loop control.
Accessing Channel Parameters with Modbus
For channel parameters the Modbus address offsets correspond
to the channel numbers. (Note that channel numbers are not
affected by the analog input selected as the Process Variable
Source or the output selected as the Output Destination (Heat/Cool
Output Dest).)
For example, register addresses for Heat Proportional Band (Heat
Prop Band) for channels 1-48 are 43101 to 43148. Channel 1’s
Heat Proportional Band is stored at address 43101. Channel 2’s
Heat Proportional Band is stored at address 43102, and so on.
Table 5.12 on page 174 lists first and last Modbus addresses for
each channel parameter. Use these addresses when accessing
channel parameters with third-party software or operator
interface terminals.
172
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Chapter 5: LogicPro and Modbus Reference
Accessing Channel Parameters with LogicPro
When a logic program variable accesses a channel parameter,
the parameter number (#) and the channel number (database
offset) are used in conjunction with the LogicPro’s Database
IO Driver. The IO Physical Address is constructed from the
parameter number and the channel number.
See the LogicPro User’s Guide for specific instructions on
addressing channel parameters. See Table 5.12 on page 174 for
channel parameter numbers.
Channel Parameters for Heat and Cool Outputs
Each of the PPC’s closed-loop control channels may have one or
two outputs (heat and/or cool). Many of the channel parameters
may be independently set for the heat and cool outputs and,
therefore, have two registers in the database. For example, Heat
Proportional Band (Heat Prop Band) is the proportional band for the
heat output and Cool Proportional Band (Cool Prop Band) is the
proportional band for the cool output.
Channel Parameters
Table 5.12 lists the parameter number (#), range, and first and
last Modbus addresses for each channel parameter. These
values are used when accessing channel parameters with
third-party software, operator interface terminals or LogicPro
programs.
The range of some of the parameters is equal to the range of the
input type selected for the channel. See Table 5.10 on page 170
for a list of the input types and their corresponding ranges.
While all the channel parameter values are 16-bit integers,
many, such as Control Mode, are numerical representations of
settings that have special meanings to the controller. See the
tables under the corresponding parameter descriptions for
explanations of the possible settings.
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Table 5.12
Channel Parameters
#
Range
Modbus
Address
Process Variable
Source
99
0-324
46101-46150
17D4-1805
Process Variable
96
33001-33050
BB8-BE9
Setpoint
95
46051-46100
17A2-17D3
Control Mode
1
0-3
40001-40050
0-31
Heat Feedback Value
13
0-1000
30151-30200
96-C7
Cool Feedback Value
25
0-1000
30351-30400
15E-18F
Heat Proportional Band
3
40101-40150
64-95
Cool Proportional Band
15
40451-40500
1C2-1F3
Heat Integral
4
0-600
40151-40200
96-C7
Cool Integral
16
0-600
40501-40550
1F4-225
Heat Derivative
5
0-255
40201-40250
C8-F9
Cool Derivative
17
0-255
40551-40600
226-257
Spread
2
40051-40100
32-63
Heat Manual Reset
8
0-1000
40301-40350
12C-15D
Cool Manual Reset
20
0-1000
40601-40650
258-289
Control Type
19
0-4
46401-46450
1900-1931
Setpoint Source
7
0-324
40251-40300
FA-12B
Setpoint Ratio
9
-30000-30000
40351-40400
15E-18F
Setpoint Offset
14
-32767-32767
40401-40450
190-1C1
See explanation on p. 182
Maximum Setpoint
26
46451-46500
1932-1963
See explanation on p. 182
Minimum Setpoint
27
46501-46550
1964-1995
See explanation on p. 182
Parameter
Hex
Address
Notes
See explanation on p. 179
See Table 5.18 on page 180
PID Parameters
See explanation on p. 180
See explanation on p. 181
See explanation on p.182
Output Parameters
Heat Output Type
30
0-25
40651-40700
28A-2BB
See Table 5.19 on page 183
Cool Output Type
45
0-25
41201-41250
2BCO-2BF1
See Table 5.19 on page 183
Heat Output Cycle Time
32
1-255
40751-40800
2EE-31F
Cool Output Cycle Time
47
1-255
41301-41350
514-545
Heat Scale Lo
38
0-1000
41051-41100
41A-44B
Cool Scale Lo
53
0-1000
41601-41650
2D50-2D81
Heat Scale Hi
39
0-1000
41101-41150
2B5C-2B8D
Cool Scale Hi
54
0-1000
41651-41700
672-6A3
Heat Curve
35
0-2
40901-40950
384-3B5
See Table 5.21 on page 184
Cool Curve
50
0-2
41451-41500
5AA-5DB
See Table 5.21 on page 184
Auto Heat Limit
33
0-1000
40801-40850
320-351
Auto Cool Limit
48
0-1000
41351-41400
546-577
Heat Limit Time
34
0-32767
40851-40900
352-383
174
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Chapter 5: LogicPro and Modbus Reference
#
Range
Modbus
Address
Cool Limit Time
49
0-32767
41401-41450
578-5A9
Sensor Fail Heat%
37
0-1000
41001-41050
3E8-419
Sensor Fail Cool%
52
0-1000
41551-41600
60E-63F
Heat Output Filter
31
0-100
40701-40750
2BC-2ED
Cool Output Filter
46
0-100
41251-41300
4E2-513
Heat Output%
36
0-1000
40951-41000
3B6-3E7
Cool Output%
51
0-1000
41501-41550
5DC-60D
Heat Output Destination
40
0-4102
41151-41200
47E-4AF
Cool Output Destination
55
0-4102
41701-41750
6A4-6D5
Alarm Status Flags
82
*
45451-45500
154A-157B
See Table 5.28 on page 190
Alarm Control Flags
85
*
45601-45650
15E0-1611
See Table 5.30 on page 192
Alarm Acknowledge
Flags
88
*
45751-45800
1676-16A7
See Table 5.31 on page 192
Alarm Enable Flags
91
*
45901-45950
170C-173D
See Table 5.32 on page 192
High Process Limit
80
45351-45400
14E6-1517
Low Process Limit
83
45501-45550
157C-15AD
High Deviation Offset
86
45651-45700
1612-1643
Low Deviation Offset
89
45801-45850
16A8-16D9
Alarm Deadband
92
0-255
45951-46000
173E-176F
Alarm Delay
93
0-100
46001-46050
1770-17A1
High Process Output
Destination
81
0-336
3103-4102
45401-45450
1518-1549
Low Process Output
Destination
84
0-336
3103-4102
45551-45600
15AE-15DF
High Deviation Output
Destination
87
0-336
3103-4102
45701-45750
1644-1675
Low Deviation Output
Destination
90
0-336
3103-4102
45851-45900
16DA-170B
Parameter
Hex
Address
Notes
Alarm Parameters
See explanation on p. 193
* 16-bit binary number
NOTE!
Refer to Setting up Control Channels on page 92 for
the basics of setting up closed-loop control channels.
Process Variable Source (PV Source)
This variable determines the input used as the process variable
for this channel. The process variable is a hardware input
converted to engineering units. A value of 0 indicates a channel
with no input. See Table 5.13 on page 176 through Table 5.17
on page 179 for a list and explanation of input numbering.
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Table 5.13
Value
Input Name
(AnaWin3 Input Spreadsheet)
1
PPC1:AI 1.1
2
PPC1:AI 1.2
…
…
32
PPC1:AI 1.32
33
PPC1:AI 2.1
34
PPC1:AI 2.2
…
…
64
PPC1:AI 2.32
65
PPC1:AI 3.1
66
PPC1:AI 3.2
…
…
96
PPC1:AI 3.32
97
PPC1:AI 4.1
98
PPC1:AI 4.2
…
…
176
Process Variable and Setpoint Source
Settings for Analog Inputs on the
PPC-202x Modules
128
PPC1:AI 4.32
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PPC-2000 User’s Guide
Chapter 5: LogicPro and Modbus Reference
Table 5.14
Doc.# 30002-00 Rev 2.3
Process Variable and Setpoint Source
Settings for Encoder Inputs on the
PPC-2030 Modules
Values
Input Name
(AnaWin3 Input Spreadsheet)
129
PPC1:EIAO 11.1.1 C
130
PPC1:EIAO 11.2.1 F
131
PPC1:EIAO 11.1.2 C
132
PPC1:EIAO 11.2.2 F
133
PPC1:EIAO 11.1.3 C
134
PPC1:EIAO 11.2.3 F
135
PPC1:EIAO 11.1.4 C
136
PPC1:EIAO 11.2.4 F
137
PPC1:EIAO 12.1.1 C
138
PPC1:EIAO 12.2.1 F
139
PPC1:EIAO 12.1.2 C
140
PPC1:EIAO 12.2.2 F
141
PPC1:EIAO 12.1.3 C
142
PPC1:EIAO 12.2.3 F
143
PPC1:EIAO 12.1.4 C
144
PPC1:EIAO 12.2.4 F
145
PPC1:EIAO 13.1.1 C
146
PPC1:EIAO 13.2.1 F
147
PPC1:EIAO 13.1.2 C
148
PPC1:EIAO 13.2.2 F
149
PPC1:EIAO 13.1.3 C
150
PPC1:EIAO 13.2.3 F
151
PPC1:EIAO 13.1.4 C
152
PPC1:EIAO 13.2.4 F
153
PPC1:EIAO 14.1.1 C
154
PPC1:EIAO 14.2.1 F
155
PPC1:EIAO 14.1.2 C
156
PPC1:EIAO 14.2.2 F
157
PPC1:EIAO 14.1.3 C
158
PPC1:EIAO 14.2.3 F
159
PPC1:EIAO 14.1.4 C
160
PPC1:EIAO 14.2.4 F
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Table 5.15
Value
Input Name
(AnaWin3 Input Spreadsheet)
161
PPC1:Proc 0.1.1 C
162
PPC1:Proc 0.2.1 F
Table 5.16
Process Variable and Setpoint Source
Settings for Soft Input and Channel
Out Registers
Value
Input Name
(AnaWin3 Input Spreadsheet)
165
PPC1:Soft Input 1
166
PPC1:Soft Input 2
…
…
212
PPC1:Soft Input 48
213
Reserved
214
Reserved
215
PPC1:Channel 1 Out
216
PPC1:Channel 2 Out
…
…
178
Process Variable and Setpoint Source
Settings for Counter Inputs on the
PPC-2010 Module
262
PPC1:Channel 48 Out
263
Reserved
264
Reserved
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Chapter 5: LogicPro and Modbus Reference
Table 5.17
NOTE!
Process Variable and Setpoint Source
Settings for Counter Inputs on the
PPC-2040 Modules
Values
Input Name
(AnaWin3 Input Spreadsheet)
301
PPC1:DIO 21.1.1 C
302
PPC1:DIO 21.2.1 F
303
PPC1:DIO 21.1.2 C
304
PPC1:DIO 21.2.2 F
305
PPC1:DIO 22.1.1 C
306
PPC1:DIO 22.2.1 F
307
PPC1:DIO 22.1.2 C
308
PPC1:DIO 22.2.2 F
309
PPC1:DIO 23.1.1 C
310
PPC1:DIO 23.2.1 F
311
PPC1:DIO 23.1.2 C
312
PPC1:DIO 23.2.2 F
313
PPC1:DIO 24.1.1 C
314
PPC1:DIO 24.2.1 F
315
PPC1:DIO 24.1.2 C
316
PPC1:DIO 24.2.2 F
317
PPC1:DIO 25.1.1 C
318
PPC1:DIO 25.2.1 F
319
PPC1:DIO 25.1.2 C
320
PPC1:DIO 25.2.2 F
321
PPC1:DIO 26.1.1 C
322
PPC1:DIO 26.2.1 F
323
PPC1:DIO 26.1.2 C
324
PPC1:DIO 26.2.2 F
The range of values and the precision of the Process
Variable and Setpoint depend on the Input Type of the
analog input selected as the Process Variable Source
for the channel. See Table 5.10 on page 170.
Process Variable
This register contains the actual value measured by the sensor
attached to the input set as the Process Variable Source for the
channel (see above). The process variable is used in the
channel’s feedback calculation. This register is read-only.
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Setpoint
The setpoint is the desired value for the process variable. The
setpoint may be set to any value within the range of the type of
the input selected as the Process Variable Source for the channel.
If the setpoint set is out of the defined range, the controller
assigns the closest number within the range.
Control Mode
This parameter indicates the mode of control for the channel.
Table 5.13 lists and describes the values to which this
parameter can be set.
Table 5.18
Value
Control Mode
Mode
Description
0
Off
Control algorithm is inactive and no output
is set.
1
Manual
Output is set by the user or a logic program.
See Heat Output and Cool Output in this
section.
2
Auto
Output is determined by the PID or on/off
control algorithm.
Tune
The PPC determines and sets the proportional band, derivative and integral parameters for the channel by setting the output
and measuring the system’s response. See
Autotuning on page 93.
3
Heat/Cool Feedback Value
The raw output value in parts per thousand (0.1%) calculated
by the PID algorithm. In a normal control loops this value is
filtered with the output filter before it becomes the Heat Output
or Cool Output.
Heat/Cool Proportional Band (Heat/Cool Prop Band)
The proportional band is used to calculate PID output. Larger
numbers result in less proportional action for a given error or
deviation from setpoint. This parameter is set in engineering
units to a positive value less than the sensor range.
Heat/Cool Integral
The integral term controls the amount of influence the history
of error has on the output. Increasing the integral value
decreases the integral contribution to the output. Zero is a
special case that disables integral action. This value is in
seconds per repeat.
180
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Chapter 5: LogicPro and Modbus Reference
Heat/Cool Derivative
The derivative term controls the amount of influence the rate
of change of the error has on the output. A greater value yields
a greater derivative action. The derivative constant is in units
of seconds.
Spread
This is the offset between heat and cool modes when both heat
and cool outputs for a channel are used. The spread is also the
switching hysteresis for on/off channels. The spread is set in
the channel’s engineering units to a positive value less than the
sensor range.
Heat/Cool Manual Reset
Enter a value to add to the PID output calculation. When the
corresponding Integral is set to zero, the value substitutes for
the integral sum portion of the feedback calculation. In this
case, the output equals the manual reset value when the
process variable is at setpoint. When the integral value is set to
a value other than zero, the manual reset value is added to the
result of the PID calculation and, thereby, shifts the output
variable.
This parameter is set in tenths of a percent. The valid range is
0 to 1000 and corresponds to 0.0% to 100.0%: for example, a
setting of 500 corresponds to 50.0%.
Control Type
Select the function of the channel.
Table 5.19
Doc.# 30002-00 Rev 2.3
Control Types
Value
AnaWin3 Name
Description
0
PID1
Heat and Cool outputs, only one
on at a time.
1
PID2
Heat and Cool outputs, both may
be on.
3
Reserved
4
Retransmit
Watlow Anafaze
n/a
Retransmit one or two analog
inputs
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Setpoint Source
This parameter determines how the setpoint for the channel is
set. Select User for normal closed-loop control applications.
Select a channel output (Channel # Out) for cascade control.
Select an analog input for ratio control, differential control,
remote setpoint, or process variable retransmit. A value of 0
indicates a user set setpoint. See Table 5.13 on page 176
through Table 5.17 on page 179 for values to select a channel
output or analog input as the source of the setpoint value.
Setpoint Ratio
For ratio control, differential control, and remote setpoint
applications, set the ratio by which the analog input value
selected as the Setpoint Source is multiplied to calculate the
setpoint. (See Ratio Control on page 109, Differential Control
on page 112, and Remote Set Point on page 112.) This
parameter may be set to any value from -30000 to 30000
corresponding to a range of -300.00 to 300.00.
Setpoint Offset
For ratio control, differential control, and remote setpoint
applications set the offset which is added to the product of the
analog input value selected as the Setpoint Source and the
Setpoint Ratio to calculate the setpoint. (Ratio Control on page
109,Differential Control on page 112, and Remote Set Point on
page 112.)
This parameter may be set to any value from -32768 to 32767
The number of decimal places depends on the Input Type
selected. See Table 3.15 on page 130.
Maximum Setpoint
This parameter determines the maximum value the PPC will
accept for the setpoint of the channel. This parameter is also
used to scale a cascade channel. (See Cascade Control on page
105). The range is the same as that of the input type for the
channel.
Minimum Setpoint
This parameter determines the minimum value the PPC will
accept for the setpoint of the channel. This parameter is also
used to scale a cascade channel. (See Cascade Control on page
105). The range is the same as that of the input type for the
channel.
Heat/Cool Output Type
This parameter specifies the type of output signal and
determines whether the PID or on/off control algorithm is used
for the channel. See Table 5.20 on page 183. For specific
information on control terminology and definitions, refer to
Chapter 6, Control Terminology.
182
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Chapter 5: LogicPro and Modbus Reference
Table 5.20
Value
Description
Destinations
Digital output from a
PPC-2010, PPC-2040 or
PPC-206x, Soft Bool
internal database value.
0
Time Prop
Digital, time
proportioned
1
DZC
Digital, distributed
zero crossing
Digital output from a
PPC-2010 or PPC-2040
Digital, on/off
Digital output from a
PPC-2010, PPC-2040, or
PPC-206x, Soft Bool
internal database value.
2
3-14
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AnaWin3
Name
Output Types
On/Off
Reserved
15
Internal Count
16
Analog 0-20mA
Analog output type,
0-20mA
17
Analog 4-20mA
Analog output type,
4-20mA
18
Analog 0-5Vdc
Analog output type,
0-5Vdc
19
Analog 1-5Vdc
Analog output type,
1-5Vdc
20
Analog 0-10Vdc
Analog output type,
0-10Vdc
21
SDAC 0-20mA
Serial digital-to-analog converter, 020mA
22
SDAC 4-20mA
Serial digital-to-analog converter, 420mA
23
SDAC 0-5Vdc
Serial digital-to-analog converter, 05Vdc
24
SDAC 1-5Vdc
Serial digital-to-analog converter, 15Vdc
25
SDAC 0-10Vdc
Serial digital-to-analog converter, 010Vdc
Internal analog
software (register)
Watlow Anafaze
Soft Int internal database
value.Stored in the database in the PPC-2010.
No additional hardware
required. Cannot drive
field I/O device directly.
Analog output using a
PPC-2030 or PPC-2050
Soft Int internal database
value.
Analog output using a
digital output from the
PPC-2010 module
connected to a peripheral
SDAC module.
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Heat/Cool Cycle Time
Specify the time base in seconds for time proportional outputs.
The output percentage is proportioned over this time period.
For example, a 50% output with a 10-second cycle time is on for
5 seconds and off for 5 seconds. Output cycle time only affects
control when the corresponding output type is set to Digital Time
Proportioning (Time Prop).
Heat/Cool Scale Lo
A control output may be linearly scaled by setting this
parameter. Set the percent of the output range of the selected
Heat/Cool Output Type that should correspond to a calculated Heat/
Cool Output% of 0%.
This parameter is set in tenths of a percent. The valid range is
0 to 1000 and corresponds to 0.0% to 100.0%: for example, a
setting of 500 corresponds to 50.0%.
Heat/Cool Scale Hi
A control output may be linearly scaled by setting this
parameter. Set the percent of the output range of the selected
Heat/Cool Output Type that should correspond to a calculated Heat/
Cool Output% of 100%.
This parameter is set in tenths of a percent. The valid range is
0 to 1000 and corresponds to 0.0% to 100.0%: for example, a
setting of 500 corresponds to 50.0%.
Heat/Cool Curve
Use this register to choose which output scaling method is
used. Straight linear is used for most applications. Lag curves
are usually used in plastic extruder applications. Table 5.21 on
page 184 lists and describes the values to which this parameter
may be set. Figure 5.2 on page 185 illustrates the effects of the
options.
Table 5.21
Value
184
Heat/Cool Curve
AnaWin3
Name
Description
0
Straight linear
Output is unaffected and is set as
calculated by the closed-loop PID
calculation.
1
Lag curve A
Output is reduced somewhat from
calculated value.
2
Lag curve B
Output is further reduced from
calculated value.
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Doc.# 30002-00 Rev 2.3
Heat/Cool Scale Lo
Set this parameter in conjunction with Heat/Cool Scale Hi to scale the output or to change the control
action. (See table 3.x.) Enter the value, as a percent of range, that the output should approach as the
process variable approaches the set point from below for a heat output or from above for a cool output.
See Figure 3.x.
The default and typical value is 0%. For example, as a heater raises the temperature of a load towards
set point, the output decreases toward 0%. In some cases it is desirable that the output never reach 0%,
in that case enter a minimum value greater than 0%.
This parameter is set in tenths of a percent. The valid range is 0 to 1000 and corresponds to 0.0% to
100.0%: for example, a setting of 500 corresponds to 50.0%.
Heat/Cool Scale Hi
Set this parameter in conjunction with Heat/Cool Scale Lo to scale the output or to change the control
action. (See table 3.x.) Enter the value, as a percent of range, that the output should approach as the
process variable moves away from the set point either upward for a heat output or downward for a cool
output. See Figure 3.x.
The default and typical value is 100%. For example, as the temperature of a heated system drops the
controller increases its output toward 100%. In some cases it is desirable that the output never reach
100%, in that case enter a maximum value less than 100%. See also Auto Heat/Cool Limit.
This parameter is set in tenths of a percent. The valid range is 0 to 1000 and corresponds to 0.0% to
100.0%: for example, a setting of 500 corresponds to 50.0%.
Note
Sometimes it is necessary for a heat output to increase as the process variable approaches the set point
from below. In such cases the Heat/Cool Scale Lo value is set above the Heat/Cool Scale Hi parameter.
(See Direct Heat in Table 3.x.) For example, in some systems heat is added outside the control loop and
the heat output controls a cooling water flow. In such a system as the temperature rises to set point, the
output increases to flow more water and slow the heating process.
Table 3.x Output Scaling Parameters Settings and Control Action
Output Control Action
Scale Lo
Scale Hi
Note
Heat
Reverse (Default)
0%
100% As the process variable increases,
Cool
Reverse
100%
0% the output decreases.
Heat
Direct
100%
0% As the process variable increases,
Cool
Direct (Default)
0%
100% the output increases.
CAUTION
When a Heat/Cool Scale Lo parameter is set to a value greater than the corresponding Heat/Cool Scale
Hi, the Heat Output % or Cool Output % values are inversely related to the actual output signal. In this
case when the Heat/Cool Output % indicates 0% the output is fully on regardless of whether the Control
Mode is set to Auto, Manual or Tune. Always remove power from the controller before servicing any
components.
Figure 3.x Heat and Cool Scaling Parameters
Process Variable (Units)
Output (%)
Set Point + Cool Prop Band
Cool Scale Hi
Cool
Cool Scale Lo
Set Point
Heat Scale Lo
Heat
Set Point - Heat Prop Band
Heat Scale Hi
Time
As the process
variable increases
toward set point,
the heat output
trends toward the
Heat Scale Lo
value
As the process
variable increases
away from set
point, the cool
output trends
toward the Cool
Scale Hi value
As the process
variable decreases
toward set point,
the cool output
trends toward the
Cool Scale Lo
value
As the process
variable decreases
away from set
point, the heat
output trends
toward the Heat
Scale Hi value
PPC-2000 User’s Guide
Chapter 5: LogicPro and Modbus Reference
Actual
Output
Applied
(%)
A
B
Calculated Closed-Loop Control Action (%)
Figure 5.2
Output Scaling Curves
Auto Heat/Cool Limit
This parameter limits the control output for a channel’s heat
and cool outputs. This limit may be continuous, or it may be in
effect for a specified number of seconds (see Heat/Cool Limit Time
below). If you choose a timed limit, the output limit restarts
when the controller powers up and when the channel changes
from Manual to Automatic control. The output limit only affects
channels under automatic control. It does not affect channels
under manual control. The valid range is 0 to 1000 and
corresponds to 0.0% to 100.0%: for example, a setting of 500
corresponds to 50.0%.
Heat/Cool Limit Time
Set a time limit for the Auto Heat/Cool Limit. If set to 0, the limit
is in effect whenever the channel is in automatic control. The
Heat/Cool Limit Time is set in seconds.
Sensor Fail Heat/Cool%
When a failed sensor alarm occurs on a channel under
automatic control, that channel goes to Manual control at this
percent power output. The valid range is 0 to 1000 and
corresponds to 0.0% to 100.0%: for example, a setting of 500
corresponds to 50.0%.
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Heat/Cool Output Filter
This parameter determines how much the heat or cool output’s
response is damped. The Heat or Cool Output responds to a step
change in Feedback Value by going to approximately 2/3 of its
final value within the number of scans set. A larger number
yields a slower, or more damped, control response to changes in
the calculated output. A value of 0 disables the filter.
Heat/Cool Output%
Set a heat or cool output value in percent when the channel is
in Manual control mode, or monitor the output in Automatic
control. For PID output types, the output is calculated based on
the heat PID parameters. The valid range is 0 to 1000 and
corresponds to 0.0% to 100.0%: for example, a setting of 500
corresponds to 50.0%.
Heat/Cool Output Destination (Heat/Cool Output Dest)
Select the output destination to specify the I/O point used for
the control output. This is the output for the closed-loop control
channel. Selecting 0 indicates no output is to be used, and is an
appropriate setting for monitor-only channels. Values are
calculated for the corresponding output whenever the output
destination has a non-zero setting. If both the heat and cool
output destinations are non-zero, the channel performs
bimodal control. See Heat and Cool Outputs on page 90. Refer
to Table 5.22 for a list of values and the corresponding physical
or software output destinations.
Table 5.22
Value
Digital I/O Name
(AnaWin3 Dig I/O Spreadsheet)
1
PPC1:Proc 0.0.1
2
PPC1:Proc 0.0.2
…
…
186
Output Destinations for Digital
Outputs on the PPC-2010 Module
48
PPC1:Proc 0.0.48
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PPC-2000 User’s Guide
Chapter 5: LogicPro and Modbus Reference
Table 5.23
Value
Digital I/O Name
(AnaWin3 Dig I/O Spreadsheet)
49
PPC1:DIO 21.0.1
50
PPC1:DIO 21.0.2
…
…
80
PPC1:DIO 21.0.32
81
PPC1:DIO 22.0.1
82
PPC1:DIO 22.0.2
…
…
112
PPC1:DIO 22.0.32
113
PPC1:DIO 23.0.1
114
PPC1:DIO 23.0.2
…
…
144
PPC1:DIO 23.0.32
145
PPC1:DIO 24.0.1
146
PPC1:DIO 24.0.2
…
…
176
PPC1:DIO 24.0.32
177
PPC1:DIO 25.0.1
178
PPC1:DIO 25.0.2
…
…
208
PPC1:DIO 25.0.32
209
PPC1:DIO 26.0.1
210
PPC1:DIO 26.0.2
…
…
Doc.# 30002-00 Rev 2.3
Output Destinations for Digital
Outputs on the PPC-2040 Modules
240
PPC1:DIO 26.0.32
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Table 5.24
Value
Digital I/O Name
(AnaWin3 Dig I/O Spreadsheet)
241
PPC1:DO 41.1
242
PPC1:DO 41.2
…
…
256
PPC1:DO 41.16
257
PPC1:DO 42.1
258
PPC1:DO 42.2
…
…
272
PPC1:DO 42.16
273
PPC1:DO 43.1
274
PPC1:DO 43.2
…
…
288
PPC1:DO 43.16
289
PPC1:DO 44.1
290
PPC1:DO 44.2
…
…
304
PPC1:DO 44.16
305
PPC1:DO 45.1
306
PPC1:DO 45.2
…
…
320
PPC1:DO 45.16
321
PPC1:DO 46.1
322
PPC1:DO 46.2
…
…
188
Output Destinations for Digital Outputs on the PPC-206x Modules
336
PPC1:DO 46.16
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Chapter 5: LogicPro and Modbus Reference
Table 5.25
Value
Output Name
(AnaWin3 Outputs Spreadsheet)
1001
PPC1:EIAO 11.3.1
1002
PPC1:EIAO 11.3.2
1003
PPC1:EIAO 11.3.3
1004
PPC1:EIAO 11.3.4
1005
PPC1:EIAO 12.3.1
1006
PPC1:EIAO 12.3.2
1007
PPC1:EIAO 12.3.3
1008
PPC1:EIAO 12.3.4
1009
PPC1:EIAO 13.3.1
1010
PPC1:EIAO 13.3.2
1011
PPC1:EIAO 13.3.3
1012
PPC1:EIAO 13.3.4
1013
PPC1:EIAO 14.3.1
1014
PPC1:EIAO 14.3.2
1015
PPC1:EIAO 14.3.3
1016
PPC1:EIAO 14.3.4
Table 5.26
Output Destinations for Analog
Outputs on the PPC-205x Modules
Value
Output Name
(AnaWin3 Outputs Spreadsheet)
1017
PPC1:AO 31.1
1018
PPC1:AO 31.2
…
…
1024
PPC1:AO 31.8
1025
PPC1:AO 32.1
1026
PPC1:AO 32.2
…
…
1032
PPC1:AO 32.8
1033
PPC1:AO 33.1
1034
PPC1:AO 33.2
…
…
1040
PPC1:AO 33.8
1041
PPC1:AO 34.1
1042
PPC1:AO 34.2
…
…
Doc.# 30002-00 Rev 2.3
Output Destinations for Analog
Outputs on the PPC-2030 Modules
1048
PPC1:AO 34.8
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Table 5.27
Output Destinations for Soft
Boolean and Soft Integers
Value
AnaWin3 Name
(Soft Bool and Soft Int1 Spreadsheets)
3001
PPC1:Soft Bool 1
3002
PPC1:Soft Bool 2
…
…
4000
PPC1:Soft Bool 1000
2051
PPC1:Soft Int 1
2052
PPC1:Soft Int 2
…
…
2150
PPC1:Soft Int 100
1Soft
Integers 1-100 may be used as output destinations.
Extended Soft Integers 101-2100 may not be used as output
destinations.
NOTE!
See Alarms on page 95 for an overview of alarm
functions.
Alarm Status Flags
Each Alarm Status register contains a 16-bit word. The bits may
be read to detect the status of each of a channel’s alarms. When
an alarm occurs, the controller sets the appropriate bit equal to
one. When the alarm condition clears, the controller sets the bit
back to 0. Table 5.28 summarizes these definitions. See Table
5.29 on page 191 for alarm bit definitions.
Table 5.28
Alarm Status
Value
190
Condition
0
No alarm condition exists
1
Alarm condition exists
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Chapter 5: LogicPro and Modbus Reference
Table 5.29
Alarm Bit Definitions
Bit
Alarm Name
1 (least significant)
Spare
2
Spare
3
Low deviation
4
High deviation
5
Low process
6
High process
7
Spare
8
Spare
9
T/C break (or open)
10
RTD open
11
RTD short
12
Spare
13
Spare
14
Ambient Temperature
15
Spare
16 (most significant)
Spare
ç
CAUTION!
Failed sensor alarms are only checked on inputs
associated with channels. Any input that is not
selected as the PV Source of a channel will not
generate failed sensor alarms.
Alarm Control Flags
Each Alarm Control register contains a 16-bit word. The bits
determine the behavior of the various alarms. Setting an Alarm
Control bit to 1 makes the corresponding alarm behave as a
control. Setting a bit to 0 makes it behave as a standard alarm.
Table 5.30 on page 192 describes the difference between
standard alarms and controls. See Table 5.29 for alarm bit
definitions.
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Table 5.30
Value
0
1
Alarm and Control Functionality
Function
Description
Alarm
Standard alarm function. Digital output, if
set, activates on alarm, deactivates when
channel is not in alarm. Global alarm
output activates and requires alarm
acknowledgment to clear.
Control
Digital output, if set, activates on alarm,
deactivates when channel is not in alarm.
Global alarm output does not activate. No
alarm acknowledgment required to clear.
Alarm Acknowledge Flags
Each Alarm Acknowledge register contains a 16-bit word. When
an alarm occurs and it is not a control alarm, the corresponding
Alarm Acknowledge bit is set equal to 1. The bit remains set even
if the corresponding alarm condition is corrected. Read the
Alarm Acknowledge bits to determine if there are
unacknowledged alarms. Set bits to 0 to acknowledge the
corresponding alarm.
Table 5.31
Alarm Acknowledge
Value
Description
0
Acknowledged alarm
1
Unacknowledged alarm
Alarm Enable Flags
Alarm Status and Alarm Acknowledge bits are set when the process
variable crosses the process or deviation limit only when the
corresponding alarm enable bit set to 1. Set the alarm enable
bit to 1 for each alarm limit to be monitored. Set the alarm
enable bit to 0 to ignore the corresponding alarm.
Table 5.32
Alarm Enable/Disable
Value
NOTE!
192
Description
0
Disable
1
Enable
The range and precision of the process limits and
deviation offsets are the same as that of the
corresponding input. See Table 5.10 on page 170.
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High Process Limit (HP Limit)
The high process alarm activates when the Process Variable (PV)
goes above the high process setpoint. The PV must drop to the
alarm setpoint minus the alarm deadband for the alarm to
clear. The alarm limit is set in the engineering units of the
channel. Its value does not change when the process setpoint
changes. The default high process alarm setpoint is 0.
Low Process Limit (LP Limit)
The low process alarm activates when the process variable (PV)
goes below the low process setpoint. The PV must rise to the
alarm setpoint plus the alarm deadband for the alarm to clear.
The alarm limit is set in the engineering units of the channel.
Its value does not change when the process setpoint changes.
The default low process alarm setpoint is 0.
High Deviation Offset (HD Offset)
This value determines the high deviation alarm limit relative
to the current setpoint. The high deviation alarm occurs when
the process variable is greater than the current setpoint plus
this value. The offset is set in the engineering units of the
channel but relative to the process setpoint. The alarm limit
changes when the process setpoint changes. The default high
deviation offset is 0.
Low Deviation Offset (LD Offset)
This value determines the low deviation alarm limit relative to
the current setpoint. The low deviation alarm occurs when the
process variable is lower than the current setpoint less this
value. The offset is set in the engineering units of the channel
but relative to the process setpoint. The alarm limit changes
when the process setpoint changes. The default low deviation
offset is 0.
Alarm Deadband
This parameter prevents the process and deviation alarms
from toggling on and off when the process variable is near the
alarm limit. For high alarms the deadband is below the
setpoint; for low alarms the deadband is above the setpoint. An
alarm that occurs when the process variable crosses the alarm
setpoint does not clear until the process returns within the
alarm setpoint and the deadband value. The deadband is set in
the engineering units of the channel. The default alarm
deadband is 2.
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Alarm Delay
This value delays alarm reporting, to prevent the reporting of
false alarms due to noise on the input. The alarm delay applies
to failed sensor alarms and process and deviation alarms. Only
alarms that are present for longer than the alarm delay time
are reported. The alarm delay is set in seconds.
NOTE!
Use the Database Offset number of an output for the
alarm output value. See Table 5.33 on page 196
through Table 5.36 on page 199.
If more than one alarm is assigned to the same output
number, that output will be on if any of those alarms
is active.
High Process Output Destination (HP Output Dest)
Choose the digital output that is toggled when the high process
alarm occurs. This can be any available hardware output or a
Boolean register accessible to the logic program. The default
high process alarm output is 0. When 0 is selected there is no
output.
Low Process Output Destination (LP Output Dest)
Choose the digital output that is toggled when the low process
alarm occurs. This may be any available hardware output a
Boolean register accessible to the logic program. The default
alarm output is 0. When 0 is selected there is no output.
High Deviation Output Destination (HD Output Dest)
Choose the digital output that is toggled when the high
deviation alarm occurs. This may be any available hardware
output or a Boolean register accessible to the logic program.
The default alarm output is 0. When 0 is selected there is no
output.
Low Deviation Output Destination (LD Output Dest)
Choose the digital output that is toggled when the low
deviation alarm occurs. This may be any available hardware
output or a Boolean register accessible to the logic program.
The default alarm output is 0. When 0 is selected there is no
output.
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Digital I/O Parameters in the Database
Digital I/O parameters determine the state and behavior of
digital inputs and outputs found on the PPC’s Processor,
Digital I/O, Digital Input and Digital Output modules.
State and Logic
The State registers containing the value of the digital I/O point
must be interpreted in terms of the Logic, in order to determine
the physical state of the I/O point.
For example, if the State is 1 and the Logic is 1=On, the
corresponding input or output is on. For a dc digital input this
indicates the input is connected to the power supply common.
For an ac input this indicates the signal is detected. For a
digital output or relay output this indicates the output is
conducting.
Conversely, if the State is 1 and the Logic is 0=On, the
corresponding input or output is off. For an input, this indicates
the field device is an open circuit. For an open collector output,
this indicates the output is an open circuit. For a relay output,
this indicates the output is de-energized.
Accessing Digital I/O Parameters with Modbus
For Digital I/O parameters, the Modbus address offsets
correspond to the digital I/O numbers. See Table 5.33 on page
196 through Table 5.36 on page 199 for a list of the module I/O
numbers corresponding to the digital I/O on the Processor and
Digital I/O modules.
Addresses for digital I/O State, Direction, Logic are relative to the
hardware connection to the corresponding field I/O device. For
example, the PPC-2000 processor module has 48 digital I/O
points with registered addresses 1 to 48. The state of the device
connect to pin 1 on the TB50 is stored at address 03001. The
state of the device connected to pin 2 on the TB50 is stored at
address 03002, and so on.
Table 5.38 on page 200 lists first and last Modbus addresses for
each digital I/O parameter. Use these addresses when
accessing digital I/O parameters with third-party software or
operator interface terminals.
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Accessing Digital I/O Parameters with LogicPro
When a logic program variable accesses a digital input State,
the LogicPro IO Physical Address is used in conjunction with
the LogicPro IO Driver for the corresponding module type. See
Table 5.33 on page 196 to determine the LogicPro IO Physical
Address.
The LogicPro IO Physical Addresses are listed by I/O point
according to the default names as seen in AnaWin3. To
correlate the AnaWin3 name with the hardware connection see
Table 2.10 on page 39, Table 2.23 on page 72, and Table 2.24 on
page 76. When a logic program variable accesses a digital I/O
parameter, the parameter number (#) and the Database Offset
are used in conjunction with the LogicPro’s Database IO
Driver. The IO Physical Address is constructed from the
parameter number and the database offset.
See the LogicPro User’s Guide for specific instructions on
addressing digital I/O parameters. See Table 5.33 on page 196
for a list of the database offsets for each digital I/O point. See
Table 5.38 on page 200 for digital I/O parameter numbers.
Digital I/O Numbers and Address Offsets
Table 5.33 lists the LogicPro IO Physical Address, Database
Offsets and sample Modbus address corresponding to each
digital I/O point.
Table 5.33
AnaWin3 Name1
(Dig I/O Spreadsheet)
Database Offsets and Sample
Modbus Addresses for Digital I/O
LogicPro I/O Physical Address2
Modbus Addressing
Processor_2010
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:Proc 0.0.1
0.0.1
#.1
1
00001
PPC1:Proc 0.0.2
0.0.2
#.2
2
00002
…
…
…
…
…
PPC1:Proc 0.0.48
0.0.48
#.48
48
00048
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Digital I/O on page
132 for a full explanation of digital I/O naming.
2LogicPro Variable Type must be BOOL.
3Use this address with the Processor_2010 IO Driver when addressing State.
4Use this address with the Database IO Driver when addressing input parameters other than
State. Replace the # with the parameter number (#) from Table 5.38 on page 200 for the parameter you want to address.
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Table 5.34
AnaWin3 Name1
(Dig I/O Spreadsheet)
Addresses for Digital I/O on the
PPC-2040 Digital I/O Modules
LogicPro I/O Physical Address2
Modbus Addressing
Digital_IO_2040
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:DIO 21.0.1
21.0.1
#.49
49
00049
PPC1:DIO 21.0.2
21.0.2
#.50
50
00050
…
…
…
…
…
PPC1:DIO 21.0.32
21.0.32
#.80
80
00080
PPC1:DIO 22.0.1
22.0.1
#.81
81
00081
PPC1:DIO 22.0.2
22.0.2
#.82
82
00082
…
…
…
…
…
PPC1:DIO 22.0.32
22.0.32
#.112
112
00112
PPC1:DIO 23.0.1
23.0.1
#.113
113
00113
PPC1:DIO 23.0.2
23.0.2
#.114
114
00114
…
…
…
…
…
PPC1:DIO 23.0.32
23.0.32
#.144
144
00144
PPC1:DIO 24.0.1
24.0.1
#.145
145
00145
PPC1:DIO 24.0.2
24.0.2
#.146
146
00146
…
…
…
…
…
PPC1:DIO 24.0.32
24.0.32
#176
176
00176
PPC1:DIO 25.0.1
25.0.1
#.177
177
00177
PPC1:DIO 25.0.2
25.0.2
#.178
178
00178
…
…
…
…
…
PPC1:DIO 25.0.32
25.0.32
#.208
208
00208
PPC1:DIO 26.0.1
26.0.1
#.209
209
00209
PPC1:DIO 26.0.2
26.0.2
#.210
210
00210
…
…
…
…
…
PPC1:DIO 26.0.32
26.0.32
#.240
240
00240
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Digital I/O on page
132 for a full explanation of digital I/O naming.
2LogicPro Variable Type must be BOOL.
3Use this address with the Digital_IO_2040 IO Driver when addressing State.
4Use this address with the Database IO Driver when addressing digital I/O parameters other
than State. Replace the # with the parameter number (#) from Table 5.38 on page 200 for the
parameter you want to address.
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Table 5.35
AnaWin3 Name1
(Dig I/O Spreadsheet)
Addresses for Digital Outputs on the
PPC-206x Digital Out Modules
LogicPro I/O Physical Address2
Modbus Addressing
Digital_Out_206x
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:DO 41.1
41.1
#.241
241
00241
PPC1:DO 41.2
41.2
#.242
242
00242
…
…
…
…
…
PPC1:DO 41.16
41.16
#.256
256
00256
PPC1:DO 42.1
42.1
#.257
257
00257
PPC1:DO 42.2
42.2
#.258
258
00258
…
…
…
…
…
PPC1:DO 42.16
42.16
#.272
272
00272
PPC1:DO 43.1
43.1
#.273
273
00273
PPC1:DO 43.2
43.2
#.274
274
00274
…
…
…
…
…
PPC1:DO 43.16
43.16
#.288
288
00288
PPC1:DO 44.1
44.1
#.289
289
00289
PPC1:DO 44.2
44.2
#.290
290
00290
…
…
…
…
…
PPC1:DO 44.16
44.16
#.304
304
00304
PPC1:DO 45.1
45.1
#.305
305
00305
PPC1:DO 45.2
45.2
#.306
306
00306
…
…
…
…
…
PPC1:DO 45.16
45.16
#.320
320
00320
PPC1:DO 46.1
46.1
#.321
321
00321
PPC1:DO 46.2
46.2
#.322
322
00322
…
…
…
…
…
PPC1:DO 46.16
46.16
#.336
336
00336
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Digital I/O on page
132 for a full explanation of digital I/O naming.
2LogicPro Variable Type must be BOOL.
3Use this address with the Digital_Out_206x IO Driver when addressing State.
4Use this address with the Database IO Driver when addressing digital I/O parameters other
than State. Replace the # with the parameter number (#) from Table 5.38 on page 200 for the
parameter you want to address.
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Table 5.36
AnaWin3 Name1
(Dig I/O Spreadsheet)
Addresses for Digital Inputs on the
PPC-207x Digital In Modules
LogicPro I/O Physical Address2
Modbus Addressing
Digital_In_207x
IO Driver3
Database
IO Driver4
Database
Offset
Sample
Address
PPC1:DI 51.1
51.1
#.337
337
00337
PPC1:DI 51.2
51.2
#.338
338
00338
…
…
…
…
…
PPC1:DI 51.16
51.16
#.352
352
00352
PPC1:DI 52.1
52.1
#.353
353
00353
PPC1:DI 52.2
52.2
#.354
354
00354
…
…
…
…
…
PPC1:DI 52.16
52.16
#.368
368
00368
PPC1:DI 53.1
53.1
#.369
369
00369
PPC1:DI 53.2
53.2
#.370
370
00370
…
…
…
…
…
PPC1:DI 53.16
53.16
#.384
384
00384
PPC1:DI 54.1
54.1
#.385
385
00385
PPC1:DI 54.2
54.2
#.386
386
00386
…
…
…
…
…
PPC1:DI 54.16
54.16
#.400
400
00400
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Digital I/O on page
132 for a full explanation of digital I/O naming.
2LogicPro Variable Type must be BOOL.
3Use this address with the Digital_In_207x IO Driver when addressing State.
4Use this address with the Database IO Driver when addressing digital I/O parameters other
than State. Replace the # with the parameter number (#) from Table 5.38 on page 200 for the
parameter you want to address.
Digital I/O Uses
The Processor module and the Digital I/O modules have 48
I/O points each. These modules have configurable I/O. Some or
all of their points can be individually configured as either an
input or an output by setting a bit in the Direction register.
24 of the 48 I/O points on the Processor module are
configurable. 22 I/O points are fixed as outputs. The remaining
two I/O points are reserved for the global alarm and CPU fail/
system OK signals.
Some I/O points can be used for frequency or counter inputs or
serial digital-to-analog (SDAC) outputs.
Refer to Table 5.37 on page 200 for specific information.
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Table 5.37
Digital I/O Uses
PPC-2010
PPC-2040
PPC-2061
PPC-2062
PPC-2070
PPC-2072
PPC-2071
PPC-2073
Configurable I/O points
1-24
1-32
n/a
n/a
n/a
n/a
Output only points
25-46
n/a
1-16
1-8
n/a
n/a
n/a
n/a
n/a
n/a
1-8
1-16
Pulse or counter inputs
1
1-2
n/a
n/a
n/a
n/a
Digital outputs that may
be used as SDACs
41-45
n/a
n/a
n/a
n/a
n/a
Reserved outputs (Global
Alarm, CPU Watchdog)
47, 48
n/a
n/a
n/a
n/a
n/a
46
n/a
n/a
n/a
n/a
n/a
Use
Input only points
SDAC clock output
Digital I/O Parameters
Table 5.38 lists the parameter number (#), range, and first and
last Modbus addresses for each digital I/O parameter. These
values are used when accessing digital I/O parameters with
third-party software, operator interface terminals or LogicPro
programs.
All the digital I/O parameters are 1 bit values and, therefore,
have a range of 0-1. See the tables under the corresponding
parameter descriptions for explanations of the possible
settings.
Table 5.38
Digital I/O Parameters
#
Range
Modbus
Address
State
130
0-1
00001-03560
0-DE7
Direction
132
0-1
01001-02000
3E8-7CF
Logic
133
0-1
02001-03000
7D0-BB7
Parameter
Hex
Address
State
This register stores a logical bit which together with the
corresponding Logic bit determines the physical state of digital
outputs and indicates the state of digital inputs. When writing
to these bits, the controller will ignore any data being written
to an I/O point configured as an input. Table 5.39 on page 201
lists and describes possible combinations of State and Logic
values.
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Table 5.39
State and Logic
State Value
Logic Value
Description
0
0(1=On)
Input signal detected or output is
energized
0
1(0=On)
Input signal not detected or output is de-energized
1
0(1=On)
Input signal detected or output is
energized
1
1(0=On)
Input signal not detected or output is de-energized
Direction
Select whether the flexible I/O points are being used as inputs
or outputs. All flexible I/O points default to inputs. See Table
5.37 on page 200 for restrictions on particular I/O points.
Table 5.40
Direction
Value
State
0
Input
1
Output
Logic
Specify the active, true level (On state) for each system digital
output.
Table 5.41
Doc.# 30002-00 Rev 2.3
Logic
Value
State
0
1=On
1
0=On
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Analog Output Parameters in the Database
Analog Output Value is the only analog output parameter. The
analog output registers determine the levels of signals output
by the analog outputs on the Encoder In Analog Out modules.
Accessing Analog Outputs with Modbus
The Modbus address offsets for Analog Output Value correspond
to the analog output. See Table 5.42 on page 203 and Table 5.43
on page 204 for a list of the analog outputs and the
corresponding Modbus addresses.
The table lists first and last Modbus addresses for each module
with analog outputs. Use these addresses when accessing
analog output values with third-party software or operator
interface terminals.
Accessing Analog Outputs with LogicPro
When a logic program variable accesses an Analog Output Value,
the LogicPro IO Physical Address is used in conjunction with
the LogicPro IO driver for the corresponding module type.
The LogicPro IO Physical Addresses are listed by output
according to the default output names as seen in AnaWin3. To
correlate the AnaWin3 name with the hardware connection see
Table 2.20 on page 60 and Table 2.22 on page 67.
See the LogicPro User’s Guide for specific instructions on
addressing analog outputs. See Table 5.42 and Table 5.43 for a
list of the LogicPro IO Physical Addresses corresponding to the
analog outputs.
Analog Outputs and Modbus Addresses
Table 5.42 and Table 5.43 list the LogicPro I/O physical
address and Modbus address for each Analog Output Value
corresponding to the modules, module addresses and module
output numbers of each analog output.
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Table 5.42
Addresses for Analog Outputs on the
PPC-2030 Encoder In Analog Out
Modules
LogicPro I/O Physical
Address
Modbus Addressing
Encoder_Analog_2030
IO Driver2
Decimal
Hex
PPC1:EIAO 11.3.1
11.3.1
46201
1838
PPC1:EIAO 11.3.2
11.3.2
46202
1839
PPC1:EIAO 11.3.3
11.3.3
46203
183A
PPC1:EIAO 11.3.4
11.3.4
46204
183B
PPC1:EIAO 12.3.1
12.3.1
46205
183C
PPC1:EIAO 12.3.2
12.3.2
46206
183D
PPC1:EIAO 12.3.3
12.3.3
46207
183E
PPC1:EIAO 12.3.4
12.3.4
46208
183F
PPC1:EIAO 13.3.1
13.3.1
46209
1840
PPC1:EIAO 13.3.2
13.3.2
46210
1841
PPC1:EIAO 13.3.3
13.3.3
46211
1842
PPC1:EIAO 13.3.4
13.3.4
46212
1843
PPC1:EIAO 14.3.1
14.3.1
46213
1844
PPC1:EIAO 14.3.2
14.3.2
46214
1845
PPC1:EIAO 14.3.3
14.3.3
46215
1846
PPC1:EIAO 14.3.4
14.3.4
46216
1847
Name1
AnaWin3
(Output
Spreadsheet)
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Outputs on page
135 for a full explanation of analog output naming.
2Use this address with the Encoder_Analog_2030 IO Driver when addressing Analog Output Value. There are no other analog output parameters so you will not use the Database IO Driver.
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Table 5.43
Addresses for Analog Outputs on the
PPC-205x Analog Out Modules
LogicPro I/O Physical
Address
Name1
AnaWin3
(Output Spreadsheet)
Modbus Addressing
Analog_Out_205x
IO Driver2
Decimal
Hex
PPC1:AO 31.1
31.1
46267
187A
PPC1:AO 31.2
31.2
46268
187B
…
…
…
…
PPC1:AO 31.8
31.8
46274
1881
PPC1:AO 32.1
32.1
46275
1882
PPC1:AO 32.2
32.2
46276
1883
…
…
…
…
PPC1:AO 32.8
32.8
46282
1889
PPC1:AO 33.1
33.1
46283
188A
PPC1:AO 33.2
33.2
46284
188B
…
…
…
…
PPC1:AO 33.8
33.8
46290
1891
PPC1:AO 34.1
34.1
46291
1892
PPC1:AO 34.2
34.2
46292
1893
…
…
…
…
PPC1:AO 34.8
34.8
46298
1899
1The
AnaWin3 names are shown for the first PPC-2000 in the system. See Outputs on page
135 for a full explanation of analog output naming.
2Use this address with the Analog_Out_205x IO Driver when addressing Analog Output Value.
There are no other analog output parameters so you will not use the Database IO Driver.
Analog Output Value
An array of addressable I/O words that represent the output
value for each analog output as a number between 0 and 32767.
These numbers correspond to the minimum and maximum
output signal levels for the selected Output Type. The analog
signal range is determined by the hardware, jumper
configuration, and the setting of the Output Type for the channel
with the output selected as Heat/Cool Output Destination.
Range: 0 to 32767
NOTE!
204
The resolution of the analog outputs is 12 bit. The
output Value is displayed as a 15-bit integer. The
output Value must change by more than seven to
effect a measurable change in an analog output.
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Soft Bool and Soft Int Registers in the Database
The database provides 1000 1-bit (Boolean) registers and 2100
word (Integer) registers that may be accessed both by a logic
program and by AnaWin3 or third-party software.
Table 5.44 lists the parameter number, range, and first and
last Modbus addresses for each Soft Bool and Soft Int
parameter.
Table 5.44
Soft Bool and Soft Int Parameters
Parameter
#
Range
Modbus
Address
Hex Address
Soft Bool
134
0-1
3001-4000
BB8-F9F
Soft Int
136
-32,768 to 32,767
46301-46400
189C-18FF
Extended Soft Int
137
-32,768 to 32,767
47001-49000
1B58-2327
Accessing Soft Bool and Soft Int Registers with Modbus
The Boolean and Integer registers are accessed by Modbus
address. Table 5.46 on page 206 lists first and last Modbus
addresses for the Boolean and Integer registers. Use these
addresses when accessing Boolean and Integer registers with
third-party software or operator interface terminals.
Accessing Soft Bool and Soft Int Registers with LogicPro
When a logic program variable accesses a Boolean or Integer
register, the database offset is used in conjunction with the
LogicPro Soft_Bool or Soft_Int I/O driver. The LogicPro IO
Physical Address is constructed from the database offset only.
See the LogicPro User’s Guide for specific instructions on
addressing Boolean and Integer registers. See Table 5.46 on
page 206 for the LogicPro IO Physical Address of each register.
Soft Bool and Soft Int Registers
Table 5.46 lists the LogicPro IO Physical Address ranges,
database offsets and first and last Modbus addresses for the
Boolean and integer registers. These values are used when
accessing Boolean and Integer registers with third-party
software, operator interface terminals or LogicPro programs.
Table 5.45
Doc.# 30002-00 Rev 2.3
Soft Bool Values
Value
AnaWin3 Value
0
1
False
True
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These registers may be chosen as output destinations for a
channel. See Table 5.27 on page 190 for a list of output
destinations values that includes these registers.
Table 5.46
Soft Bool and Soft Int Registers
AnaWin3 Name
(Soft Bool and Soft
Int Spreadsheets)
LogicPro I/O Physical
Address1
PPC1: Soft Bool 1
PPC1: Soft Bool 2
Modbus Addressing
Decimal
Hex
1
3001
BB8
2
3002
BB9
…
…
…
…
PPC1: Soft Bool 1000
1000
4000
F9F
PPC1: Soft Int 1
1
46301
189C
PPC1: Soft Int 2
2
46302
189D
…
…
…
…
PPC1: Soft Int 100
100
46400
18FF
PPC1: Soft Int 101
101
47001
1B58
PPC1: Soft Int 102
102
47002
1B59
…
…
…
…
PPC1: Soft Int 2100
2100
49000
2327
1Use
this address with the Soft_Bool or Soft_Int IO Driver when addressing the Soft Boolean
and Soft Integer Registers.
Global Parameters in the Database
These system parameters are global and not relative to
channels or I/O hardware addresses.
Accessing Global Parameters with Modbus
Some global parameters have only one Modbus address others
use a range of addresses. Table 5.48 on page 208 and Table 5.51
on page 209 list first and last Modbus address for the global
parameters. Use Modbus addresses when accessing global
parameters with third-party software or operator interface
terminals.
See the parameter descriptions for addressing details.
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Chapter 5: LogicPro and Modbus Reference
Accessing Global Parameters with LogicPro
When a logic program variable accesses global parameters, the
parameter number (#) and the offset are used in conjunction
with the LogicPro Database I/O driver. The I/O physical
address is constructed from the parameter number and the
database offset.
See the LogicPro User’s Guide for specific instructions on
addressing global parameters. See Table 5.48 on page 208 and
Table 5.51 on page 209 for the parameter number (#) and the
parameter descriptions for database offsets for each global
parameter.
Communications Parameters
For multiple PPC installations, each PPC must have a unique
network address. As many as 32 PPC systems may
communicate on a network. Network addresses 1 through 4 can
be set using the rotary switch on the processor module.
Use setting D and PPCComSU to program the remaining
addresses (5-32). Refer to Setting Programmable Modbus
Addresses on page 87 for programming information.
Changed communication parameters do not take affect until
the controller resets or cycles power, and only with the
appropriate rotary switch settings on the Processor module.
NOTE!
Do not cycle power with the rotary switch set in
positions E-G unless specifically directed to do so.
These positions are used for clearing memory and
other functions. Parameter settings can be lost. See
Chapter 4, Troubleshooting, for more on these switch
settings.
Table 5.47
Doc.# 30002-00 Rev 2.3
Rotary Switch Configuration
Position
Network Address
A
Fixed: 1
B
Fixed: 2
C
Fixed: 3
D
Programmable, Default: 4
E-G
N/A
H
Fixed: 1
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Switch settings A-D have the following settings:
•
19.2 kbaud (programmable)
•
Even parity (fixed)
•
8 data bits (fixed)
•
1 stop bit (fixed)
Switch setting H has the following fixed settings:
•
19.2 kbaud
•
Even parity
•
8 data bits
•
1 stop bit
Switch settings E-G are Reserved.
Table 5.48 lists the parameter number (#) range, and first and
last Modbus addresses for the communications parameters.
Table 5.48
Communications Parameters
Parameter
#
Baud Rate
119
Address
122
Range
1-247
Modbus
Address
Hex
Address
46171-46180
181A-1823
46191-46200
182E-1837
Baud Rate
Select the communications baud rate for the corresponding
port.
Table 5.49
Database Offsets for Baud Rate
Database Offset
Description
1
Port 1
2
Port 2
Table 5.50
Baud Rate
Value
Baud Rate
9600
9600
19200
19200
Address
This is the Modbus communications network address to which
the PPC will answer on ports 1 and 2.
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Chapter 5: LogicPro and Modbus Reference
Global Database Parameters
Table 5.51 lists parameter number (#), range, and first and
last Modbus addresses for the remaining global parameters.
These values are used when accessing global parameters with
third-party software, operator interface terminals or LogicPro
programs.
Table 5.51
System HW Parameters
#
Range
Modbus
Address
Hex
Address
Notes
Full Scale
142
-32768
to 32767
33451-33500
D7A-DAB
See Table 5.52
Zero Reference
143
-32768
to 32767
33501-33550
DAC-DDD
See Table 5.54
Modules Present
113
0-255
33551-33750
DDE-EA5
See Table 5.56
and Table 5.57
Ambient Temperature
140
-32768
to 32767
33751-33770
EA6-EB9
See Table 5.55
Parameter
Table 5.52
Miscellaneous System Parameters
#
Range
Modbus
Address
System Status
106
0-1
10001-10050
0-31
See Table 5.59
and Table 5.60
System Commands
105
0-1
04051-04100
FD2-1003
See Table 5.57
Changed Data Queue
107
0-255
33051-33150
BEA-C4D
Program Version
108
0-255
33151-33200
C4E-C7F
System Error Log
112
0-255
33201-33450
C80-D79
Time and Date
114
0-99
46151-46157
672-678
Parameter
Hex
Address
Notes
See Table 5.60
See Table 5.63
Full Scale
The values stored in the Full Scale registers are the readings
from the high voltage references. These readings are used in
conjunction with the zero reference readings to scale the analog
input readings.
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Table 5.53
Full Scale Readings
Database
Offset
Module
Address
1
2
3
4
5
6
7
8
1
1
2
2
3
3
4
4
Range
-1 to 10V
-5 to 50mV
-1 to 10V
-5 to 50mV
-1 to 10V
-5 to 50mV
-1 to 10V
-5 to 50mV
Reference
Voltage
10V
50mV
10V
50mV
10V
50mV
10V
50mV
Zero Reference
The values stores in the Zero Reference registers are the
readings from the low voltage reference. These readings are
used in conjunction with the Full Scale reading to scale the
analog input readings.
Table 5.54
210
Zero Reference Readings
Database
Offset
Module
Address
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
Watlow Anafaze
Range
-1 to 10V
-0.5 to 5V
-0.1 to 1V
-50 to 500mV
-10 to 100mV
-5 to 50mV
-1 to 10V
-0.5 to 5V
-0.1 to 1V
-50 to 500mV
-10 to 100mV
-5 to 50mV
-1 to 10V
-0.5 to 5V
-0.1 to 1V
-50 to 500mV
-10 to 100mV
-5 to 50mV
-1 to 10V
-0.5 to 5V
-0.1 to 1V
-50 to 500mV
-10 to 100mV
-5 to 50mV
Reference
Voltage
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
0V
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Chapter 5: LogicPro and Modbus Reference
Ambient Temperatures
The analog input modules measure the temperatures of each
terminal block on up to 4 AITBs in tenths of a degree
Fahrenheit.
These give the cold junction compensation temperature in
degrees F for each half of the terminal block. Note that the
channel numbers associated with a given cold junction
reference depend on whether the card is single ended or
differential.
Table 5.55
Ambient Temperature Readings
Associated
AITB
Connectors
Database
Offset
Module Address
1
1
TB1 and TB2
2
1
TB3 and TB4
3
2
TB1 and TB2
4
2
TB3 and TB4
5
3
TB1 and TB2
6
3
TB3 and TB4
7
4
TB1 and TB2
8
4
TB3 and TB4
Modules Present
Eight registers are required to describe the features and
capabilities of each module. As many as 12 modules may be
inventoried on start-up, totalling 96 registers. After the
inventory routines run, the registers are updated with the
current configuration. Refer to Table 5.56 and Table 5.57 on
page 212. These settings are read-only.
Table 5.56
Modules Present
Database
Offset
Doc.# 30002-00 Rev 2.3
Description
Range
1
Type of Module
2
Module number (rotary switch address)
0-14
3
Number of digital inputs
0-48
4
Number of digital outputs
0-48
5
Number of analog inputs
0-32
6
Number of analog outputs
0-8
7
Number of frequency / counter inputs
0-4
8
Reserved
n/a
Watlow Anafaze
0-9
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For modules with configurable I/O, the total number of
potential inputs and outputs are set in the corresponding
registers. For example, the Processor module inventory returns
24 digital inputs and 46 digital outputs. The count of analog
outputs does not include outputs that can be configured for
SDACs.
Table 5.57
Module Types
Value
Description
0
No module
1
PPC-2010
2
Reserved
3
PPC-2021, 2024, 2025
4
PPC-2022
5
PPC-2030
6
PPC-2040
7
PPC-2050, 2051
8
PPC-2061, 2062
9
PPC-2070, 2071, 2072, 2073
System Commands
System Commands force specific actions within the controller.
Write a 1 in the register to execute the corresponding
command. Some command bits are executed and reset to 0 by
the controller immediately after a host writes a 1. Other
command bits are latched in whatever state was last written.
Table 5.58 lists each type.
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Chapter 5: LogicPro and Modbus Reference
Table 5.58
Database
Offset
Doc.# 30002-00 Rev 2.3
Modbus
Address
System Commands
Name
Reset
After
Host
Write
Action
Load defaults to most run-time
parameters. The exceptions are
protocol, baud, parity, address,
system HW config, system commands, system status, program
version, change data queue,
system error log, real time clock
and analog input calibration
data.
1
04051
Reload
Defaults
Reset
2
04052
Reserved
N/A
3
04053
Reserved
N/A
4
04054
RAM Clear
Reset
Reset
Clear RAM, reset controller and
load defaults
5
04055
Watchdog
Test
Reset
Force watchdog timeout
6
04056
Start Logic
Reset
Start logic program
7
04057
Reserved
N/A
8
04058
Stop Logic
Reset
Stop logic program
9
04059
Loop
Startup
Latched
0=Start control loops in off
mode. Undo not available.
1=Start control loops from last
mode stored in memory.
10
04060
AC
Frequency
Latched
0=60Hz
1=50Hz
11
04061
Logic Startup
Latched
0=Start logic program when
commanded.
1=Start logic program on startup.
12
04062
Reset PPC
Reset
Reset controller
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System Status
Provides information about various controller functions and
errors. These values are read-only. Some status bits are sets to
0 after being read by a host. Other status bits are not affected
by host reads and are latched in whatever state the controller
determines. See Table 5.59 .
Table 5.59
System Status
Reset
After
Host
Read
Database
Offset
Modbus
Address
1
10001
Defaults
Loaded
Reset
2
10002
Reserved
N/A
3
10003
Reserved
N/A
4
10004
Controller
has reset
Reset
Controller has reset
5
10005
Ambient
Status
Latched
Ambient
temperature error
6
10006
H/W Cfg
Status
Latched
Hardware
configuration error
7
10007
Battery
Status
Latched
Battery voltage is low
14
10014
Logic Run
Status
Latched
Logic program is running
15
10015
Logic Load
Status
Latched
Logic program is loaded
Name
Description
Default values have
been loaded
The values of the bits in the System Status Registers are
interpreted according to the following table:
Table 5.60
System Status Bits
Value
Status
0
no error / false
1
error / true
Program Version
Embedded program version label for the firmware program.
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Chapter 5: LogicPro and Modbus Reference
Table 5.61
Program Version Information
Database Offset
Description
1
Major version, first digit
2
Major version, second digit
3
Minor version, first digit
4
Minor version, second digit
5
Release level alpha character
6
Reserved
7
Reserved
8
Reserved
Changed Data Queue
The Changed Data Queue is a tool for hosts which need to
maintain a mirror image database of the PPC-2000 database.
Typically, these are PC based hosts. Most simple operator
interfaces, such as operator interface terminals, constantly
query the PPC for only the information that needs to be
displayed on the current screen. These devices would not read
the queue.
The PPC-2000 can communicate with 1 or 2 host devices with
read/write capability. If 2 hosts are used, the changed data
queue alerts port 1 host that port 2 host has changed a
section(s) of the database and vice versa. Each port has a
dedicated queue which must be continuously monitored by the
respective host. The addresses are the same for both ports, but
the data in each queue may differ because port 1 queue
monitors port 2 activity while port 2 queue monitors port 1
activity.
The queue consists of a group of read-only registers. Register
33051 contains the quantity of parameters which have been
changed by the other host. Registers 33052-N form a first-infirst-out stack of changed parameters consisting of the
parameter ID numbers. The queue does not report the changed
status of specific elements within a parameter but only the
parameter ID number that has been changed. Therefore, if the
changed data queue notifies host 1 that host 2 has changed a
parameter, it is necessary for host 1 to read all elements within
a parameter to update host 1's database.
Using a First In First Out (FIFO) stack, the queue logs all
changes to the database originating from another host.
Register 33052 contains the oldest change logged, 33053
contains the second oldest and so on. After the host reads the
register(s), the data is cleared and shifted in the FIFO stack.
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It is necessary to begin any host read command (Modbus
function 04) with register 33051. Read requests that do not
start at 33051 are not supported. It is not necessary to
continually read the entire queue at once. A recommended
technique is to read the first 8 registers of the queue on a
periodic basis. If there are more than 7 changes in the queue,
then subsequent changes would be shifted down so that the
next time the queue is read the host will pick up the changes.
System Error Log
The System Error log indicates how many times particular
failures have occurred since the last time the error log was
cleared. The first register contains a total count of system
errors. The last register contains a number of unidentified or
illegal error codes logged. Refer to Table 5.62 on page 217. The
counts stop incrementing at 255.
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Chapter 5: LogicPro and Modbus Reference
Table 5.62
System Error Log
Database
Offset
Modbus
Address
1
33201
Error Count
Total error count (255 maximum)
22
33222
Logic Checksum
Bad checksum in a logic program hex record
24
33224
Logic Load
Error verifying programming of a logic program hex
record
42
33242
Undefined Parm#
Parameter number outside the range of the database
43
33243
Bad Data Sent
Attempt to write data outside of a parameter’s range
44
33244
Bad Offset
Parameter offset beyond last element of the parameter
45
33245
Parm Size
Internal error in parameter size during read or write
47
33247
Database Reg
Internal error registering database entry
48
33248
Write to RO
Attempt was made to write to a read only variable
49
33249
Change Q Overflow
Overflow in database change queue
51
33251
Bad Flash Type
Flash type was not found in table
52
33252
Flash Overflow
Attempted write past end of flash
53
33253
Program Verify
Failed program verify test
61
33261
Bad Interrupt
Received bad interrupt
66
33266
Divide by Zero
Divide by zero exception
67
33267
Illegal OpCode
Illegal opcode exception
71
33271
AI Address
Multiple AI boards detected at one address
73
33273
AI Cal Data
AI board has invalid calibration data
74
33274
AI Timeout
System unable to process AI input on time
75
33275
CMO or Open T/C
CMO or OTC occurred on an AI channel
92
33292
Bad Baud Rate
Configured baud rate not supported
93
33293
UART Not Found
A UART not detected
94
33294
Wrong Port
Internal error: attempt to configure unsupported port
96
33296
Closed Port
Internal error: attempt to access port that isn’t open
97
33297
Bad Parity
Internal error: attempt to configure unsupported parity
101
33301
Bad CRC
Modbus message CRC did not match
102
33302
Bad Modbus Func
Modbus message attempted unsupported function
103
33303
Invalid Address
Invalid Modbus register address
104
33304
Pckt Ln or Func
Bad Modbus packet length or diagnostic subfunction
107
33307
Packet Length
Bad Modbus packet length
108
33308
Bad Address
Bad Modbus register address
111
33311
Missed I/O Update
Internal error: missed I/O update deadline
129
33329
Bad Error Msg
Internal error: attempted to post error of 128 or greater
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Name
Description
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Time and date
The PPC-2000’s clock calendar automatically updates the year,
day of the week, month, date, hour, minute and second. The
time and date can be set initially with a PC or similar host. The
information located in seven registers can be used in logic
programs or a host computer. Table 5.63 describes the data
format.
Table 5.63
Real Time Clock Format
Database
Offset
Description
Range
0
Year
0 to 99
1
Day of Week1
1 to 7
2
Month
1 to 12
3
Date
1 to 31
4
Hours
0 to 23
5
Minutes
0 to 59
6
Seconds
0 to 59
1 The
values for day of the week are not predefined. They are incremented with the date. The user chooses what day equals a value of one, and the rest of the day values follow.
218
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6
Tuning and Control
This chapter describes the different methods of control
available with the your controller. This section covers:
•
On/Off Control
•
Proportional Control
•
Proportional and Integral Control
•
PID Control
•
Control Outputs
•
Tuning PID Loops
•
PID Constants by Application
Introduction
This chapter explains PID control and supplies some starting
PID values and tuning instructions to help appropriately set
control parameters in the PPC system. For more information
on PID control, consult the Watlow Anafaze Practical Guide to
PID.
The control algorithm dictates how the controller responds to
an input signal. Do not confuse control algorithms with control
output signals (for example, analog or pulsed DC voltage).
There are several control algorithms available: On/Off,
Proportional (P), Proportional and Integral (PI), Proportional
with Derivative (PD), and Proportional with Integral and
Derivative (PID). P, PI, or PID control is necessary when process
variable (PV) cycling is unacceptable or if the process or setpoint
(SP) is variable.
NOTE!
Doc.# 30002-00 Rev 2.3
For any of these control modes to function, the
channel must be in automatic mode.
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Control Algorithms
The next sections explain the different methods for controlling
a loop.
On/Off Control
On/Off control is the simplest way to control a process; a
controller using On/Off control turns an output on or off when
the process variable reaches limits around the desired setpoint.
This limit is adjustable; Watlow Anafaze controllers use an
adjustable spread.
For example, if the set point is 1000°F, and the spread is 20°F,
the heat output switches On when the process variable drops
below 980°F and Off when the process rises above 1000°F. A
process using On/Off control cycles around the set point. Figure
6.1 illustrates this example.
Heat off
Heat off
Heat on
PV
SP = 1000°F
SP-Spread = 980°F
On
Output
Off
Figure 6.1
220
On/Off Control
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Chapter 6: Tuning and Control
Proportional Control
Proportional control eliminates cycling by increasing or
decreasing the output in proportion to the process variable’s
deviation from the setpoint.
The magnitude of proportional response is defined by the
Proportional Band (PB); outside this band, the output is either
100% or 0%. Within the proportional band the output power is
proportional to the PV’s difference from the setpoint.
For example, if the setpoint is 1000°F and the PB is 20°F, the
output is:
•
0% when the process variable is 1000°F or above
•
50% when the process variable is 990°F
•
75% when the process variable is 985°F
•
100% when the process variable is 980°F or below.
However, a process which uses only proportional control settles
at a point above or below the setpoint; it never reaches the
setpoint by itself. This behavior is known as offset or droop.
SP
offset
PB
PV
Figure 6.2
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Proportional Control
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Proportional and Integral Control
With proportional and integral control, the integral term
corrects for offset by repeating the proportional band’s error
correction until there is no error. For example, if a process
tends to settle about 5°F below the set point, appropriate
integral control brings it to the desired setting by gradually
increasing the output until there is no deviation.
SP
PB
PV
Figure 6.3
Proportional and Integral Control
Proportional and integral action working together can bring a
process to setpoint and stabilize it. However, with some
processes the user may be faced with choosing between
parameters that make the process very slow to reach setpoint
and parameters that make the controller respond quickly, but
introduce some transient oscillations when the setpoint or load
changes.
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Chapter 6: Tuning and Control
Proportional, Integral and Derivative Control
Derivative control corrects for overshoot by anticipating the
behavior of the process variable and adjusting the output
appropriately. For example, if the process variable is rapidly
approaching the set point from below, derivative control
reduces the output, anticipating that the process variable will
reach set point. Use derivative control to reduce the overshoot
and oscillation of the process variable common to PI control.
Figure 6.4 shows a process under full PID control.
SP
PB
PV
Figure 6.4
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Proportional, Integral and
Derivative Control
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Control Outputs
The controller provides open collector and analog outputs for
control. Open collector outputs normally control the process
using solid state relays.
Open collector outputs can be configured to drive a Serial
Digital-to-Analog Converter (SDAC), that in turn, can provide
0-5Vdc, 0-10Vdc or 4-20mA control signals to operate field
output devices.
Output Control Forms
The following sections explain the various control output
signals available.
On/Off
When On/Off control is used, the output is on or off depending
on the difference between the setpoint and the process variable.
PID algorithms are not used with On/Off control. The output
variable is always off or on (0% or 100%).
Time Proportioning (TP)
With time proportioning outputs, the PID algorithm calculates
an output between 0 and 100%, which is represented by
turning on an output for that percent of a fixed, user-selected
time base or cycle time. The cycle time is the time over which
the output is proportioned, and it can be any value from 1 to
255 seconds. For example, if the output is 30% and the cycle
time is 10 seconds, then the output will be on for 3 seconds and
off for 7 seconds. Figure 6.5 shows example TP and Distributed
Zero Crossing (DZC) waveforms.
Figure 6.5
224
Example Time Proportioning and Distributed Zero Crossing Waveforms
Watlow Anafaze
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PPC-2000 User’s Guide
Chapter 6: Tuning and Control
Distributed Zero Crossing (DZC)
With DZC outputs, the PID algorithm calculates an output
between 0 and 100%, but the output is switched on a variable
time base. For each AC line cycle the controller decides whether
the power should be on or off. There is no fixed cycle time since
the decision is made for each line cycle. When used in
conjunction with a zero crossing device, such as an SSR,
switching is done only at the zero crossing of the AC line, which
helps reduce electrical noise.
Using a DZC output should extend the life of heaters. Since the
time period for 60Hz power is 16.6 ms, the switching interval is
very short and the power is applied uniformly. DZC should be
used with SSRs. Do not use DZC output for electromechanical
relays.
The combination of DZC output and a solid state relay can
inexpensively approach the effect of analog, phase-angle fired
control. Note, however, DZC switching does not limit the
current or voltage applied to the heater as phase-angle firing
does.
Analog Outputs
For analog outputs, the PID algorithm calculates an output
between 0 and 100%. This percentage of the analog output
range can be applied to an output device via an analog module
or a digital module in conjunction with an SDAC.
Output Filter
The output filter smooths PID control output signals. It has a
range of 0-255 scans, which gives a time constant of 0-170
seconds for the PPC. Use the output filter if you need to filter
out erratic output swings due to extremely sensitive input
signals, like a turbine flow signal or an open air thermocouple
in a dry air gas oven.
The output filter can also enhance PID control. Some processes
are very sensitive and would otherwise require a large PB,
making normal control methods ineffective. Using the output
filter allows a smaller PB to be used, achieving better control.
Also, use the digital filter to reduce the process output swings
and output noise when a large derivative is necessary, or to
make badly tuned PID loops and poorly designed processes
behave properly.
Doc.# 30002-00 Rev 2.3
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Chapter 6: Tuning and Control
PPC-2000 User’s Guide
Setting Up and Tuning PID Loops
After installing your control system, tune each control loop and
then set the loop to automatic control. (When tuning a loop,
choose PID parameters that will best control the process.) This
section gives PID values for a variety of heating and cooling
applications.
NOTE!
Tuning is a slow process. After adjusting a loop, allow
about 20 minutes for the change to take effect.
Proportional Band (PB) Settings
Table 6.1 shows PB settings for various temperatures in
degrees Fahrenheit.
Table 6.1
Proportional Band Settings
Temperature
Setpoint
PB
Temperature
Setpoint
PB
Temperature
Setpoint
PB
-100 to 99
20
1100 to 1199
75
2200 to 2299
135
100 to 199
20
1200 to 1299
80
2300 to 2399
140
200 to 299
30
1300 to 1399
85
2400 to 2499
145
300 to 399
35
1400 to 1499
90
2500 to 2599
150
400 to 499
40
1500 to 1599
95
2600 to 2699
155
500 to 599
45
1600 to 1699
100
2700 to 2799
160
600 to 699
50
1700 to 1799
105
2800 to 2899
165
700 to 799
55
1800 to 1899
110
2900 to 2999
170
800 to 899
60
1900 to 1999
120
3000 to 3099
175
900 to 999
65
2000 to 2099
125
3100 to 3199
180
1000 to 1099
70
2100 to 2199
130
3200 to 3299
185
As a general rule, set the PB to 10% of the setpoint below 1000°
and 5% of the setpoint above 1000°. This setting is useful as a
starting value.
Integral Settings
The controller’s Integral parameter is set in seconds per repeat.
Some other products use an integral term called Reset, in units
of repeats per minute. Table 6.2 on page 227 shows Integral
settings versus Reset settings.
226
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Chapter 6: Tuning and Control
Table 6.2
Integral Term and Reset Settings
Integral
(sec/repeat)
Reset
(repeat/min)
Integral
(sec/repeat)
Reset
(repeat/min)
30
2.0
210
0.28
45
1.3
240
0.25
60
1.0
270
0.22
90
0.66
300
0.20
120
0.50
400
0.15
150
0.40
500
0.12
180
0.33
600
0.10
As a general rule, use 60, 120, 180, or 240 as a starting value
for the Integral.
Derivative Settings
The controller’s Derivative parameter is programmed in
seconds. Some other products use a derivative term called Rate
programmed in minutes. Use the table or the formula to
convert parameters from one form to the other. Table 6.3 shows
Derivative versus Rate; Rate = Derivative/60.
Table 6.3
Derivative Term vs. Rate
Derivative
(seconds)
Rate
(minutes)
Derivative
(seconds)
Rate
(minutes)
5
0.08
35
0.58
10
0.16
40
0.66
15
0.25
45
0.75
20
0.33
50
0.83
25
0.41
55
0.91
30
0.50
60
1.0
As a general rule, set the Derivative to 15% of Integral as a
starting value.
NOTE!
Doc.# 30002-00 Rev 2.3
While the basic PID algorithm is well defined and
widely recognized, various controllers implement it
such that parameters may not be taken from one
controller and applied to another with optimum
results even if the above unit conversions are
performed.
Watlow Anafaze
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Chapter 6: Tuning and Control
PPC-2000 User’s Guide
General PID Constants by Application
This section gives PID values for many applications. They are
useful as control values or as starting points for PID tuning.
Proportional Band Only (P)
Set the Proportional Band to 7% of the Setpoint.
(Example: Setpoint = 450: Proportional Band = 31).
Proportional with Integral (PI)
Set the Proportional Band to 10% of Setpoint.
(Example: Setpoint = 450: Proportional Band = 45).
Set Integral to 60.
Set Derivative to Off.
Set the Output Filter to 2.
PI with Derivative (PID)
Set the Proportional Band to 10% of the Setpoint.
(Example: Setpoint = 450: Proportional Band = 45).
Set the Integral to 60.
Set the Derivative to 15% of the Integral.
(Example: Integral = 60: Derivative = 9).
Set the Output Filter to 2.
Table 6.4 shows general PID constants by application.
Table 6.4
General PID Constants
Proportional
Band
Integral
Derivative
Filter
Output
Type
Cycle
Time
Electrical heat with SSR
50°F
60
15
4
DZC
-
Electrical heat with EM relays
50°F
60
15
6
TP
20
Cool w/ solenoid valve
70°F
500
90
4
TP
10
Cool w/ fans
10°F
off
10
4
TP
10
Electric heat with open heat coils
30°F
20
off
4
DZC
-
Gas heat w/ motorized valves
SP>1200
60°F
120
25
100°F
240
40
8
Analog
-
Application
228
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Doc.# 30002-00 Rev 2.3
7
Specifications
The following sections contain specifications for the PPC-2000
system and each type of module. Specifications are subject to
change without notice.
System Specifications
This section contains specifications for the PPC-2000 system as
a whole.
Safety and Agency Approvals
Table 7.1 describes safety and agency approvals for the PPC2000 system. Approvals apply to all PPC-2000 modules and
peripherals except as noted in the specifications for individual
modules or peripherals on the following pages.
Table 7.1
Doc.# 30002-00 Rev 2.3
Safety and Agency Approvals
UL
C-UL
3121-1 Listed, Category II Installation, File # E212113
CE Safety
EN 61010-1
CE EMC
EN 61326, EN 55011
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Chapter 7: Specifications
PPC-2000 User’s Guide
Physical Specifications
3 Inch Min. Air
Flow Space
"A" + 0.46 in.
Width "A"
1 2 3 4
N
3.5 in.
6.6 in.
#10 Screw
4 Places
4.4 in.
1.4 in.
1.1 in.
3 to 4 in.
Typical
Figure 7.1
System Footprint
Table 7.2
PPC System Dimensions
Number of Modules
Width A
Overall Width
1
2.705 in.
3.165 in.
2
3.660 in.
4.120 in
3
4.615 in.
5.075 in.
4
5.570 in.
6.030 in.
5
6.525 in.
6.985 in.
6
7.480 in.
7.940 in.
7
8.435 in.
8.895 in.
8
9.390 in.
9.850 in.
9
10.345 in.
10.805 in.
10
11.300 in.
11.760 in.
Power Specifications
See Chapter 2, Power Supply Requirements on page 13 to
determine the power requirements for a PPC-2000 system.
230
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PPC-2000 User’s Guide
Chapter 7: Specifications
PPC-2010 Processor Specifications
Up to 32 PPCs may be connected on a network. The default
baud rate is 19200 and is configured via AnaWin3.
The processor module’s front panel has two serial
communications ports. Both Port 1 and Port 2 can be used with
either RS-232 or RS-485 connections. Each port’s baud rate,
network address and format are configured via the rotary
switch on the front panel.
The bottom panel includes a 50-pin SCSI connector and a 1028Vdc power connector.
The processor module has 48 built in digital I/O points. 24
points are outputs only: 22 of these are user configurable for
control, alarms, or logic program outputs and 2 are dedicated
to system status and the global alarm. The remaining 24 I/O
points are user-configurable as either inputs or outputs for
control, alarms, or logic.
Power / Error
LEDs
Serial Port 1
Rotary
Address Switch
RS-485
Connector
RS-232
Connector
Serial Port 2
RS-485
Connector
RS-232
Connector
Figure 7.2
Doc.# 30002-00 Rev 2.3
PPC-2010 Front View
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Chapter 7: Specifications
PPC-2000 User’s Guide
50-pin SCSI
Connector
12-28Vdc
Power
Connector
Figure 7.3
PPC-2010 Bottom View
Table 7.3
Model Number
PPC-2010
Table 7.4
Environmental Specifications
Storage Temperature
-20 to 70°C (-4º to 158°F)
Operating Temperature
0 to 60°C (32º to 140°F)
Humidity
10 to 95% non-condensing
Table 7.5
232
Processor
Physical Specifications
Weight
0.82 lbs
0.37 kg
Height
8.0 in.
203 mm
Width, including endcaps
3.2 in.
81 mm
Depth
5.25 in.
133 mm
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PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.6
Power Terminals
Captive screw cage clamp
Power Wire Gauge
24 to 12 AWG
Power Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in.-lb)
Connector on Module
SCSI-2 female
Mounting
DIN rail or panel mount
Port 1 and Port 2
SeeTable 7.13 on page 235
Table 7.7
Power Specifications
System Power Requirement
12 to 26 ± 2 Vdc
Power
3 W typical
Current (@ 12Vdc)
250mA typical @ 25ºC
Current (@ 24Vdc)
125mA typical @ 25ºC
Max. Voltage between Ground
and Common
40Vdc
Table 7.8
Doc.# 30002-00 Rev 2.3
Connections
Capacity and Programming
Digital I/O Points on Processor
46
Max. Number Digital I/O Points
288
Max. Number of Counter Inputs
17
Max. Number of Additional I/O Modules
9
Max. Number of Analog Inputs
128
Max. Number of Analog Outputs
(not counting DACs/SDACs)
48 (Requires 4 PPC-2030 and
4 PPC-2050.)
Program Capacity
Logic program memory:
128 kB. Data memory in
battery-back RAM: 60 kB
Programming Language
IEC1131-3 compliant Ladder
Diagram, SFC, and FBD
Number of Instructions
7 logic instructions, 42 applied
instructions
Logic Program Storage
Flash memory
Logic Programming Software
LogicPro
Operating System for Programming
Software
Windows95/98,
WindowsNT
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Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.9
Control Specifications
Control Modes
On/Off, P, PI, or PID
Number of Control Loops
48* programmable channels. Channels may be single or dual output
Control Outputs
Time proportioning, Distributed Zero
Crossing, On/Off or analog all independently selectable for each loop.
Time Proportioning
Cycle Time
1 to 255 seconds
Control Action
Reverse (heat) or direct (cool)
Alarm Outputs
Independently set high/low process
alarms and high/low deviation
alarms.
Tuning
Auto or manual
Soft Input Update
1 sec.
*Additional I/O modules required.
Table 7.10
Number
1
Maximum Frequency
10 kHz single-phase
Sample Rate
250 ms (4 Hz)
Voltage Levels
<0.6 = Low; 3.8V = High
Max. Input Current
0.5mA from processor with
input at 0V
Input Resistance
6 kOhms Min.
Count Range
16 bits
Table 7.11
234
Counter/Frequency Input
Specifications
Digital Input Specifications
Number
24**
Voltage Limiting and Protection
40Vdc
Voltage Levels
<0.6 = Low; 3.8V = High
Max. Input Current
0.5mA from processor with
input at 0V
Max. Switch Resistance to Pull Input
Low
1 kOhm
Min. Switch Off Resistance
27 kOhm
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Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.12
Digital Output Specifications
Number
48**
Configuration
1 global alarm
1 system status (CPU watchdog timer)
22 control outputs
24 configurable as inputs or control outputs
Max. Voltage
24Vdc
Max. Current
100mA sink to power common continuous
Off State Leakage Current, Outputs 1 to 24
100µA
Off State Leakage Current, Outputs 25-48
5µA
On State Maximum
Voltage
≤ 0.7Vdc (output to common)
** The PPC-2010 has 48 built-in digital I/O points. 24 points
are outputs only. 22 of the outputs are user configurable for PID
control, alarms or logic outputs. The other 2 outputs are
dedicated to system status and global alarm. The remaining 24
I/O points are individual configurable as either inputs or
outputs.
Table 7.13
Number of Ports
Doc.# 30002-00 Rev 2.3
Serial Interface
2
Type
RS-232 3-wire or RS-485 5-wire
Modular Jacks
RS-232: 4 position, 4 conductor (phone handset)
RS-485: RJ12 6 position, 6 conductor
Isolation
40Vdc working, ± 200Vdc peak
Baud Rate
19200 default, configurable 9600 or 19200
Error Check
CRC
# of Controllers
1 with RS-232; 32 with RS-485
Protocol
Modbus RTU
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Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-2021 - 2025 Analog In/Analog In High
Isolation Specifications
Status / Error
LEDs
Rotary
Address
Switch
Figure 7.4
PPC-2021 Front View
50-pin SCSI
Connector
Figure 7.5
236
PPC-2021 - 2025 Bottom View
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
The Analog In modules’ addresses are configured with the
rotary switch.
The bottom panel includes a 50-pin SCSI connection for the
Analog Input Terminal Board (AITB).
Table 7.14
Model Numbers
PPC-2021
16 input, analog input module, differential
PPC-2022
32 input, analog input module, single-ended
PPC-2024
8 input, high isolation analog input module
PPC-2025
16 input, high isolation analog input module
Table 7.15
Environmental Specifications
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
Humidity
10 to 95% non-condensing
Table 7.16
Physical Specifications
Weight
0.6 lbs
0.27 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
Mounting
Table 7.17
DIN rail or panel mount
Connections
Connector on Module
Table 7.18
Doc.# 30002-00 Rev 2.3
SCSI-2 female
Power Specifications
Power Requirement
4.7 W typical
Current (@ 12Vdc)
390mA typical @ 25°C
Current (@ 24Vdc)
195mA typical @ 25°C
Modules per Processor
4
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Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.19
Analog Input Specifications
Analog Inputs
8 or 16 differential
32 single-ended
Nominal Isolation
Input to bus: 500Vdc continuous
Input to frame ground: 120Vac
Between inputs: ±60Vac (PPC-2021)
Between inputs: 240Vac (PPC-2024, 2025)
Between inputs: no isolation (PPC-2022)
Calibration
Automatic zero and full scale
Normal Mode Rejection Ratio
(between + and - inputs)
60 dB @ dc to 1000Hz with 500 ohm input impedance
Common Mode Rejection Ratio*
(between input and frame ground)
120 dB @ dc to 1000Hz with 500 ohm input impedance
A/D Conversion
Integrating voltage to frequency
DC Voltage Input Range
-1 to 10Vdc;
ranges selectable
0 to 50mV,
0 to 100mV,
0 to 500mV,
0 to 1V,
0 to 5V,
0 to 10V
Current Input Range
0 to 20mA; ranges selectable
0 to 20mA or 4 to 20mA
RTD Input
100 ohm Pt, 3 wire
T/C Open Detect
2.5 kOhms or more (upscale)
Source Impedance
Measurements are within specification up to 500 ohm
source resistance
Resolution
0.003% greater than 15 bits
Accuracy (voltage)
0.05% at 25ºC (PPC-2021, 2024, 2025)
0.1% at 25ºC (PPC-2022)
Accuracy (current)
0.1% at 25ºC (PPC-2021, 2024, 2025)
0.75% at 25°C (PPC-2022)
Temperature Coefficient
<50 ppm/ºC, 0.005%/ºC
Sample Rate @ 60 Hz, PPC-2021,
PPC-2025
380 msec to sample all 16 channels (2.6 Hz)
Sample Rate @ 60 Hz, PPC-2022
666 msec to sample all 32 channels (1.5 Hz)
Sample Rate @ 60 Hz, PPC-2024
220 msec to sample all 8 channels (4.5 Hz)
*Not applicable to PPC-2022
238
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Chapter 7: Specifications
Table 7.20
Type
Temperature Sensor Accuracy
Range
Resolution
Total Accuracy
B T/C
32° to 3308°F (0 to 1820°C)
±0.32°F (±0.18°C)
±5.9°F (±3.3°C)
C T/C
32 to 4200°F (0 to 2316°C)
±0.02°F (±0.01°C)
±2.8°F (±1.6°C)
D T/C
32 to 4200°F (0 to 2316°C)
±0.02°F (±0.01°C)
±2.7°F (±1.5°C)
E T/C
-454 to 1221°F (-270 to 661°C)
±0.08°F (±0.04°C)
±1.8°F (±1.0°C)
F T/C (Platinel2)
32 to 2250°F (0 to 1232°C)
±0.19°F (±0.11°C)
±4.1°F (±2.3°C)
G T/C
32 to 4200°F (0 to 2316°C)
±0.02°F (±0.01°C)
±2.7°F (±1.5°C)
J T/C
-346 to 1598°F (-210 to 870°C)
±0.07°F (±0.04°C)
±2.1°F (±1.2°C)
K T/C
-454 to 2249°F (-270 to 1232°C)
±0.17°F (±0.09°C)
±3.9°F (±2.2°C)
N T/C
-454 to 2372°F (-270 to 1300°C)
±0.08°F (±0.04°C)
±2.7°F (±1.5°C)
R T/C
-58 to 3215°F (-50 to 1768°C)
±0.02°F (±0.01°C)
±4.6°F (±2.6°C)
RTD 100 Ohm Plat
-418 to 521°F (-250 to 272°C)
±0.04°F (±0.02°C)
±0.8°F (±0.4°C)
RTD 100 Ohm Plat
High
-418.0 to 1562.0°F
(-250.0 to 850.0°C)
±0.14°F (±0.08°C)
±4.2°F (±2.3°C)
S T/C
-58 to 3215°F (-50 to 1768°C)
±0.31°F (±0.17°C)
±5.6°F (±3.1°C)
T T/C
-454 to 752°F (-270 to 400°C)
±0.07°F (±0.04°C)
±2.1°F (±1.2°C)
Thermistor 100K Ohm
-24.78°F to 327°F
(-31.54 to 163.89°C)
±0.01°F
(±0.006°C)
±0.08°F (±0.04°C)
Table 7.21
Doc.# 30002-00 Rev 2.3
Sensor Reference Voltage Output
Voltage
10Vdc ± 0.3Vdc @ 25°C
Maximum Current
20mAdc
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Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-2030 Encoder In Analog Out Specifications
5Vdc is supplied at a maximum of 60mA per encoder. An
external terminal block is used to interface to the encoders.
The analog output is isolated (12Vac) individually from
processor and bus power common. In both voltage and current
modes, the return is to the analog common.
The PPC-2030 bottom panel includes two encoder input
15-pin HD connectors and two analog output connections with
two, 4-position plug type connectors. Each signal has a
dedicated return.
PPC-2030
4 ENCODER IN
4 ANALOG OUT
Status
LED
STATUS
MODULE
11
12
13
14
Rotary
Address
Switch
PXX-XXXXX
Figure 7.6
240
PPC-2030 Front View
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PPC-2000 User’s Guide
Chapter 7: Specifications
J4
J4 Encoder
Input
Connectors
(HD-15 female)
J3
J3 Encoder
Input
Connectors
(HD-15 female)
J2
J1
22+
11+
J2 Analog
Output Terminal
Block
J1 Analog
Output Terminal
Block
Figure 7.7
PPC-2030 Bottom View
Table 7.22
Model Number
PPC-2030
4 Encoder Input / 4 Analog Output Module
Table 7.23
Environmental Specifications
Storage Temperature
-20 to 70ºC
Operating Temperature
0 to 60ºC
Humidity
10 to 95% non-condensing
Table 7.24
Doc.# 30002-00 Rev 2.3
44+
33+
Physical Specifications
Weight
0.62 lbs
0.28 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
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Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.25
Connections
Mounting
DIN rail or panel mount
Terminals
Captive screw cage clamp
Connector
High Density D-sub 15 female
contact
Screw Terminal Wire Gauge
24 to 16 AWG
Screw Terminal Torque
0.22 to 0.25 Nm (1.9 to 2.2 in-lb.)
Table 7.26
Power Specifications
Power Requirement
10.8 W typical
Current (@ 12Vdc)
900mA typical @ 25ºC
Current (@ 24Vdc)
450mA typical @ 25ºC
Modules per Processor
4
Table 7.27
Input Specifications
Encoder Inputs
4
Maximum Input Frequency
10 kHz
Max Counts
10,000 counts/sec single phase
32,000 counts/sec quadrature
Sample Rate
250 ms to sample all 4 inputs (4 Hz)
Pulse Input Voltage Range:
Single-ended
242
3.0 V < V hi ≤ 5.0 V
0.0 V ≤ V lo < 2.0 V
Pulse Input Voltage Range:
Differential
±14.0 max., 0.0 to 5.0V
nominal
Input Current: Single-ended
± 1.0mA
Input Current: Differential
± 3.0mA
Count Range
16 bits
Power for Encoders
5V @ 240mA max.
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Chapter 7: Specifications
Table 7.28
Analog Outputs
4
Isolation
120Vac to power common or ground
Resolution
12 bits
Range (Voltage Mode)
0 to +10V @ 10mA maximum
Accuracy (Voltage Mode)
0.3% of reading
± 0.5% of range at 25°C
Load (Voltage Mode)
≥ 1000 ohm
Range (Current Mode)
0 to 20mA with 8V minimum
compliance (400 Ohm load)
Accuracy (Current Mode)
1.5% of reading
± 0.2% of range at 25°C
Output Update Time
0.1 sec.
Table 7.29
UL
C-UL
Doc.# 30002-00 Rev 2.3
Output Specifications
Safety and Agency Approvals
3121-1 Listed, Category II Installation, File # E212113
Watlow Anafaze
243
Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-2040 Digital I/O Specifications
The PPC-2040 provides 32 digital I/O points. Each may be
configured as an input or an output. The count and frequency
of changes to the state of the first two inputs are read as analog
inputs as well.
Status
LED
PPC-2040
32 DIGITAL I/ O
STATUS
ERROR
5
Rotary
Address
Switch
MODULE
21
22
23
26
24
25
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
I/O LEDs
PXX-XXXXX
Figure 7.8
PPC-2040 Front View
Table 7.30
Model Number
PPC-2040
Table 7.31
244
50-pin SCSI
Connector
Digital I/O
Environmental Specifications
Storage Temperature
-20 to 70ºC
Operating Temperature
0 to 60ºC
Humidity
10 to 95% non-condensing
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.32
Weight
0.82 lbs.
0.37 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
Table 7.33
Connections
Connector on Module
50-pin SCSI-2 female
Mounting
DIN rail or panel mount
Table 7.34
Power Specifications
Power Requirement
3.6 W typical
Current @ 12Vdc
300mA typical @ 25ºC
Current @ 24V
150mA typical @ 25ºC
Modules per Processor
6
Table 7.35
Doc.# 30002-00 Rev 2.3
Physical Specifications
Counter/Frequency Specifications
Number
2
Maximum Frequency
10 kHz
Max Counts
10,000 counts/sec. single-phase
32,000 counts/sec. quadrature
Sample Rate
250 ms (4 Hz)
Pulse Input Voltage Range:
Single-ended
<0.6 = Low; 3.8V = High
Maximum Current
0.5mA from module with input at 0V
Input Resistance
6 kOhms Min.
Count Range
16 bits
Watlow Anafaze
245
Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.36
Digital Input Specifications
Number
32*
Voltage Limiting and Protection
40Vdc
Logic Voltage Levels
<0.6 = Low; 3.8V = High
Maximum Current
0.5mA from processor with input at
0V
Switch Resistance to Pull Low
1 kOhms Maximum
Switch Resistance for High
27 kOhms Minimum
*The PPC-2040 has 32 digital I/O points. Each can be
configured as either an input or an output.
Table 7.37
Digital Output Specifications
Number
32*
Maximum Voltage
24Vdc
Maximum Current
150mA sink to common
Off State Leakage Current
<0.010mA up to 30Vdc
*The PPC-2040 has 32 digital I/O points. Each can be
configured as either an input or an output.
246
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
PPC-205x Analog Out Specifications
The PPC-2050 and PPC-2051 provide eight and four analog
outputs, respectively. Each output is configurable as a voltage
or current output.
Status
LED
Rotary
Address
Switch
Figure 7.9
Doc.# 30002-00 Rev 2.3
PPC-2050 Front View
Watlow Anafaze
247
Chapter 7: Specifications
PPC-2000 User’s Guide
16-pin Terminal Block
for Analog Outputs
PPC-2051
PPC-2050
Figure 7.10 PPC-2050 Bottom View
Table 7.38
PPC-2050
8 Analog Out
PPC-2051
4 Analog Out
Table 7.39
Environmental Specifications
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
°C Humidity
10 to 95% non-condensing
Table 7.40
248
Model Number
Physical Specifications
Weight
0.6 lb.
0.27 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.41
Wire Gauge
24 to 16 AWG
Screw Terminal Torque
0.22 to 0.25 Nm (1.9 to 2.2 in-lb)
Mounting
DIN rail or panel mount
Table 7.42
Power Specifications PPC-2050
Power Requirement
9.6 W typical
Current @ 12Vdc
800mA typical @ 25ºC
Current @ 24Vdc
400mA typical @ 25ºC
Table 7.43
Power Specifications PPC-2051
Power Requirement
6 W typical
Current @ 12Vdc
500mA typical @ 25ºC
Current @ 24Vdc
250mA typical @ 25ºC
Table 7.44
Doc.# 30002-00 Rev 2.3
Connections
Output Specifications
Number
8 (PPC-2050)
4 (PPC-2051)
Configuration
4 individually isolated (PPC-2051)
4 isolated pairs: 1&2, 3&4, 5&6, 7&8
(PPC-2050)
Isolation
120Vac to power common and earth ground
120Vac output-to-output (PPC-2051)
120Vac output pair-to-output pair. Paired
outputs share power supply. (PPC-2050)
Voltage Range
0 to 10Vdc @ 10mA maximum
Current Range
0 to 20mA with 8V minimum compliance
(400 Ohm load)
Voltage Accuracy
± 0.5% of range at 25ºC
Current Accuracy
± 0.8% of range at 25°C
Output Update
Time
0.1 second
Watlow Anafaze
249
Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-206x Digital Output Specifications
Status
LED
Rotary
Address
Switch
8/16 Relay
Output LEDs
Figure 7.11 PPC-206x Front View
250
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Common
Connections
PPC-2062
PPC-2061
Figure 7.12 PPC-206x Bottom View
Table 7.45
PPC-2061
16 Digital Out Relay
PPC-2062
8 Digital Out Relay
Table 7.46
Environmental Specifications
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
Humidity
10 to 95% non-condensing
Table 7.47
Doc.# 30002-00 Rev 2.3
Model Number
Connections
Screw Terminal Wire Gauge
24 to 12 AWG
Screw Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
Mounting
DIN rail or panel mount
Watlow Anafaze
251
Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.48
Weight
0.50 lbs.
0.27 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
Table 7.49
Power Specifications
Power Requirement
3 W typical
Current (@ 12Vdc)
250mA typical @ 25°C
Current (@ 24Vdc)
125mA typical @ 25°C
Modules per Processor
6
Table 7.50
252
Physical Specifications
Output Specifications
Relay Outputs
8 (PPC-2062)
16 (PPC-2061)
Relay Type
Form A (SPST NO)
Isolation
240Vac to power common or ground
Contact Arrangement
open in power off, fault or inactive condition
Maximum Load Current
2A (PPC-2062)
1A up to 5A per common (PPC-2061)
Contact Voltage Rating
240Vac, 30Vdc
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
PPC-207x Digital In Specifications
The PPC-207x modules provide 8 or 16 digital inputs. The 2070
and 2071 accept 120Vac signals. The 2072 and 2073 accept
24Vac or 24Vdc signals.
Status
LED
Rotary
Address
Switch
Input
LEDs
Figure 7.13 PPC-2070, PPC-2071 Front Views
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
253
Chapter 7: Specifications
PPC-2000 User’s Guide
Input
Connections
Common
Connections
PPC-2070
PPC-2072
PPC-2071
PPC-2073
Figure 7.14 PPC-207x Bottom Views
Table 7.51
PPC-2070
8 Digital In 120Vac
PPC-2071
16 Digital In 120Vac
PPC-2072
8 Digital In 24Vac/dc
PPC-2073
16 Digital In 24Vac/dc
Table 7.52
Environmental Specifications
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
Humidity
10 to 95% non-condensing
Table 7.53
254
Model Number
Physical Specifications
Weight
0.52 lbs
0.24 kg
Height
8.0 in.
203 mm
Width
1.5 in.
38 mm
Depth
5.25 in.
133 mm
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.54
Connections
Wire Gauge
24 to 12 AWG
Screw Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
Mounting
DIN rail or panel mount
Table 7.55
Power Specifications
Power Requirement
1.2 W typical
Current (@ 12Vdc)
100mA typical @ 25°C
Current (@ 24Vdc)
50mA typical @ 25°C
Modules per Processor
4
Table 7.56
Digital Input Specifications
Number
8 (PPC-2070, and 2072)
16 (PPC-2071 and 2073)
Input Voltage Range
70-120Vac ±10% (PPC-2070, 2071)
12-24Vac/dc ±10% (PPC-2072,2073)
120Vac
Logic Voltage Levels
Doc.# 30002-00 Rev 2.3
24Vac/dc
High > 70V
Low < 20V
High > 10V
Low < 3V
Input Response Time
32 ms (PPC-2070, 2071)
32 ms (12-24Vdc PPC-2072,2073)
32 ms (20-24Vac PPC-2072,2073)
64 ms (12-20Vac PPC-2072,2073)
Input Impedance
77 kOhms (PPC-2070, 2071)
16.9 kOhms (PPC-2072, 2073)
Input Current
1.5mA (typical) @ 120Vac or 24Vac/dc
Switch Resistance to Pull
Low
1 kOhms Maximum
Switch Resistance for High
27 kOhms Minimum
Watlow Anafaze
255
Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-AITB-1 Analog Input Terminal Block
Specifications
3.6 in.
(91 mm)
5.10 in. H
(130 mm)
4.70 in.
(119 mm)
2.3 in. D
(58 mm)
2.6 in.
(66 mm)
4.2 in. W
(107 mm)
Figure 7.15 PPC-AITB-1
Table 7.57
Environmental Specifications
Storage Temperature
Operating Temperature
Humidity
Table 7.58
Weight
Height
Width
Depth
256
-20 to 70°C
0 to 60°C
10 to 95% non-condensing
Physical Specifications
0.5 lbs
5.1 in.
4.2 in.
2.3 in.
Watlow Anafaze
0.22 kg
130 mm
107 mm
58 mm
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.59
Connections
Screw Terminal Wire Gauge
Screw Terminal Torque
Connector on Board
Terminals
Mounting
Table 7.60
Height
Width
Depth
24 to 12 AWG
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
SCSI-2 female
Captive screw cage clamp
DIN rail or panel mount
PPC-AITB with Straight SCSI
7.1 in.
4.2 in.
2.3 in.
180 mm
107 mm
58 mm
3.6 in.
(91 mm)
2.0 in.
(51 mm)
5.10 in. H
(130 mm)
4.70 in.
(119 mm)
2.3 in. D
(58 mm)
2.6 in.
(66 mm)
4.2 in. W
(107 mm)
Figure 7.16 PPC-AITB Dimensions with Straight
SCSI Cable
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
257
Chapter 7: Specifications
PPC-2000 User’s Guide
Four factory-configured input sensor keys plug into the AITB
and accommodate various input types. The following table
describes usage for the various keys:
Table 7.61
Key Type
Sensor Key Cards
Color
Code
Key Description
PPC-KEY-01
Adapts AITB for:
thermocouples (differential or single-ended)
Linear voltages (differential or single-ended)
4-wire RTDs (differential)
None
PPC-KEY-02
adapts AITB for 0-20mA linear current
(differential)
Blue
PPC-KEY-03
adapts AITB for 0-20mA linear current
(single-ended)
Black
PPC-KEY-04
adapts AITB for 2-wire RTDs (differential) or 3wire RTDs (differential)
Red
PPC-EITB-1 Encoder Input Terminal Block
Specifications
PPC-EITB Component Side
MADE IS U.S.A.
Watlow Anafaze 1997
4.0 in. H
(102 mm)
1.6 in.
(41 mm)
1.5 in. D
(38 mm)
3.4 in.
(86 mm)
2.0 in. W
(51 mm)
Figure 7.17 PPC-EITB-1
258
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.62
Environmental Specifications
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
Humidity
10 to 95% non-condensing
Table 7.63
Physical Specifications
Weight
0.10 lbs
0.05 kg
Height
4.0 in.
102 mm
Width
2.0 in.
51 mm
Depth
1.5 in.
38 mm
Mounting
Table 7.64
Connections
Screw Terminal Wire Gauge
24 to 12 AWG
Screw Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
Connector on Board
High density D-sub 15-pin female
connection
Terminals
Captive screw cage clamp
Number of Screw Terminals
12
Table 7.65
PPC-EITB with HD-Type Cable
Height
4.0 in.
102 mm
Width
2.0 in.
51 mm
Depth
2.2 in.
56 mm
Table 7.66
UL
C-UL
Doc.# 30002-00 Rev 2.3
DIN rail or panel mount
Safety and Agency Approvals
3121-1 Listed, Category II Installation, File # E212113
Watlow Anafaze
259
Chapter 7: Specifications
PPC-2000 User’s Guide
2.2 in. H
(56 mm)
PPC-EITB Component Side
MADE IS U.S.A.
Watlow Anafaze 1997
4.0 in. L
(102 mm)
1.5 in. D
(38 mm)
3.4 in.
(86 mm)
1.6 in.
(41 mm)
2.0 in. W
(51 mm)
Figure 7.18 PPC-EITB Dimensions with
HD-Type Cable
260
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
PPC-TB50-SCSI, 50-Pin Specifications
4.1 in. H
(104 mm)
4.0 in. W
(102 mm)
1.5 in. D
(38 mm)
Figure 7.19 PPC-TB50-SCSI Dimensions
Table 7.67
Storage Temperature
-20 to 70°C
Operating Temperature
0 to 60°C
Humidity
10 to 95% non-condensing
Table 7.68
Doc.# 30002-00 Rev 2.3
Environmental Specifications
Physical Specifications
Weight
0.32 lbs.
0.14 kg
Height
4.1 in.
104 mm
Width
4.0 in.
102 mm
Depth
1.45 in.
37 mm
Watlow Anafaze
261
Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.69
Connections
Screw Terminal Wire Gauge
24 to 12 AWG
Screw Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
Connector on Board
SCSI-2 female
Terminals
Captive screw cage clamp
Mounting
DIN rail or panel mount
Table 7.70
PPC-TB50-SCSI with Straight SCSI
Height
6.4 in.
163 mm
Width
4.0 in.
102 mm
Depth
1.45 in.
37 mm
6.4 in. H
(163 mm)
4.0 in. W
(102 mm)
1.5 in. D
(38 mm)
Figure 7.20 PPC-TB50-SCSI Dimensions with
Straight SCSI Cable
262
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.71
PPC-TB50-SCSI with Right Angle
SCSI
Height
5.4 in.
137 mm
Width
4.0 in.
102 mm
Depth
1.5 in.
3.7 mm
5.4 in. H
(137 mm)
4.0 in. W
(102 mm)
1.5 in. D
(38 mm)
Figure 7.21 PPC-TB50-SCSI Dimensions with
Right-Angle SCSI Cable
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
263
Chapter 7: Specifications
PPC-2000 User’s Guide
PPC-IPS-2 International Power Supply
Specifications
Watlow Anafaze offers a dual output power supply for PPC2000 systems. The PPC-IPS-2 accepts worldwide AC voltages
and outputs 5 and 24Vdc
2.5 in. min.
Air Flow Space
1.2 in.
3.1 in.
1.97 in.
Figure 7.22 PPC-IPS-2
Table 7.72
Environmental Specifications
Storage Temperature
Operation Temperature
0°C to 60°C
Humidity Conditions
20 to 90% non-condensing
Table 7.73
Physical Specifications
Weight
1.4 lbs.
0.64 kg
Height
7.8"
198 mm
Width
1.9"
48 mm
Depth
4.3"
Mounting
264
-20°C to 70°C
Watlow Anafaze
109 mm
Panel mount
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.74
Dimensions with Din Rail Bracket
Height
4.5 in.
114 mm
Width
1.9 in.
48 mm
Depth
8.5 in.
216 mm
Table 7.75
Power Specifications
Input
88 to 132Vac (115V Range)
176 to 264Vac (230V Range)
Output
V1: +5Vdc @ 6A
V2: +24Vdc @ 4A
Input Frequency
47 to 440 Hz
Peak Current Output
9A @ 5Vdc
6A @ 24Vdc
Table 7.76
Connections
Connector Type
Spade
Output Screw Terminal Wire Gauge
24 to 12 AWG
Screw Terminal Torque
0.5 to 0.6 Nm (4.4 to 5.3 in-lb.)
Table 7.77
Safety and Agency Approvals
UL
C-UL
UL 1012, UL 1950
CE
EN 60950
CE EMC
EN 55022
SDAC Specifications
Watlow Anafaze offers a Serial DAC for precision open-loop
control. The SDAC is jumper selectable for a 0-10Vdc or
4-20mA output. Multiple SDAC modules can be used with one
PPC system. The SDAC carries a CE mark.
Table 7.78
Doc.# 30002-00 Rev 2.3
Environmental Specifications
Storage Temperature
-20 to 60°C
Operating Temperature
0 to 70°C 50
Humidity
10 to 95% non-condensing
Watlow Anafaze
265
Chapter 7: Specifications
PPC-2000 User’s Guide
Table 7.79
Physical Specifications
Weight
0.76 lbs
0.34 kg
Height
5.4 in.
137 mm
Width
3.6 in.
91 mm
Length
1.75 in.
44 mm
+5
C V
C OM IN
D LK IN
FL ATA IN
=R AS IN
U HI
N N
N G
IN
G
OU
TP
CU
UT
RR
SE
EN
LT
LE
T
AG
CT
E
4
VO
{
1.75 in. H
44 mm
{
5
+
- OU
O T
U
T
3
ZE
2
C
A
D
1
FA
A
N
A
PI
N:
L
IA
R
SE
3/16 in.
(.1875)
6
4.7 in.
119 mm
3.0 in.
76 mm
3.6 in. W
91 mm
0.3 in.
8 mm
5.4 in. L
137 mm
0.4 in.
10 mm
Figure 7.23 SDAC Dimensions
Table 7.80
Safety and Agency Approvals
UL
C-UL
UL 916, File E177240
CE EMC
Directive 89/336/EEC
Inputs
The SDAC requires a proprietary serial data signal and the
clock signal from the PPC-2010 via the TB50. Any control
output can be configured to provide the data signal. The SDAC
also requires a 5Vdc power input.
266
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
PPC-2000 User’s Guide
Chapter 7: Specifications
Table 7.81
Inputs
Data
4mA maximum to dc COM
Open collector or HC CMOS logic levels
Clock
0.5mA max to dc COM
Open collector or HC CMOS logic levels
Maximum Clock Rate
10 kHz (333 updates/second)
Table 7.82
Power Requirements
Voltage
4.75 to 5.25Vdc @ 300mA max
Current
210mA typical @ 20Vdc out
Analog Outputs
Table 7.83
Absolute Maximum
Common Mode Voltage
Analog Output Specifications
Measured between output pins and controller
common: 1000V
15 bits (plus polarity bit for voltage outputs)
Resolution
(0.305mV for 10V output range)
(0.00061mA for 20mA output range)
Accuracy (calibrated for
voltage output)
For voltage output:
± 0.005V (0.05% at full scale)
For current output: +/ 0.1mA (0.5% at full scale)
Doc.# 30002-00 Rev 2.3
Temperature coefficient
440 ppm/ °C typical
Isolation Breakdown
Voltage
1000V between input power and signals
Current
0-20mA (500 Ohm load max.)
Voltage
0-10Vdc with 10mA source capability
Output Response Time
1 ms typical
Update Rate
Once per controller A/D cycle nominal. Twice
per second maximum for 60 Hz clock rate.
Output changes are step changes due to the
fast time constant. All SDAC loop outputs are
updated at the same time.
Watlow Anafaze
267
Chapter 7: Specifications
268
PPC-2000 User’s Guide
Watlow Anafaze
Doc.# 30002-00 Rev 2.3
A
Appendix A: Modbus Protocol
Watlow Anafaze offers a modbus driver (.DLL) for use with
user-written Windows-based software applications that
communicate with the PPC-2000. Using that driver makes it
unnecessary for the programmer to understand and implement
the modbus protocol.
PPC-2000 serial communications use the Modbus RTU
protocol. This protocol defines the message structure for all
communication packets. The protocol is the same for both RS232 and RS-485 serial interfaces. Modbus ASCII is not
supported.
Up to 32 PPCs may be connected on a network.
Controllers communicate using a master-slave model, in which
only one device (the master) can initiate transactions (called
“queries”). The other devices (slaves) respond by supplying the
requested data to the master, or by taking the action requested
in the query. Typical master devices include host PCs and
operator panels. The PPC-2000 is a slave device.
The master can address individual slaves, or initiate a
broadcast message to all slaves. Slaves return a message
(called a “response”) to queries that are addressed to them
individually. Responses are not returned to broadcast queries
from the master.
The Modbus protocol establishes the format for the master’s
query by placing into it the device (or broadcast) address, a
function code defining the requested action, any data to be
sent, and an error-checking field. The slave’s response message
is also constructed using Modbus protocol. It contains fields
confirming the action taken, any data to be returned, and an
error-checking field. If an error occurred in receipt of the
message, or if the slave is unable to perform the requested
action, the slave will construct an error message and send it as
its response.
Doc.# 30002-00 Rev 2.3
Watlow Anafaze
269
Appendix A: Modbus Protocol
PPC-2000 User’s Guide
Query Message from Master
Device Address
Device Address
Function Code
Function Code
Eight-Bit
Data Bytes
Error Check
Eight-Bit
Data Bytes
Error Check
Response Message from Slave
Figure A.1
Query—Response Cycle
Query
The function code in the query tells the addressed slave device
what kind of action to perform. The data bytes contain any
additional information that the slave will need to perform the
function. For example, function code 03 will query the slave to
read holding registers and respond with their contents. The
data field must contain the information telling the slave which
register to start at and how many registers to read. The error
check field provides a method for the slave to validate the
integrity of the message contents.
Response
If the slave makes a normal response, the function code in the
response is an echo of the function code in the query. The data
bytes contain the data collected by the slave, such as register
values or status. If an error occurs, the function code is
modified to indicate that the response is an error response, and
the data bytes contain a code that describes the error. The error
check field allows the master to confirm that the message
contents are valid.
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Appendix A: Modbus Protocol
Modbus ASCII and RTU Modes
Modbus protocol specifies two distinct modes: ASCII and RTU.
While the PPC-2000 only supports RTU, it is important to
understand the differences. Typically, ASCII is used for simple
communication tasks or diagnostics while RTU is used where a
more robust and efficient protocol is required.
The mode determines how messages are framed and coded. In
ASCII, each character in a message string is composed of a
hexadecimal character which is correlated to an ASCII
character. So for example, an ASCII message string contains
the value of a process variable, 5500 (550.0 degrees). 5500 in an
ASCII string is composed of 4 bytes, 35 35 30 30. 35 and 30 in
hexadecimal equate to the characters “5” and “0” in the ASCII
table respectively.
In RTU mode, the actual value is embedded in a message
string. There is no translation to ASCII characters. This results
in more compact message strings and efficient serial
communications. The value 5500 in an RTU string is composed
of its hexadecimal equivalent which is only 2 bytes, 15 7C.
Many host devices can communicate in either ASCII or RTU
mode. However, it should be noted that some PLCs can only be
an ASCII host.
Message Framing
Messages start with a silent interval of at least 3.5 character
times. This is most easily implemented as a multiple of
character times at the baud rate that is being used on the
network (shown as T1-T2-T3-T4 in the figure below). The first
field then transmitted is the device address.
Networked controllers monitor the network bus continuously,
including during the silent intervals. When the first field (the
address field) is received, each device decodes it to find out if it
is the addressed device.
Following the last transmitted character, a similar interval of
at least 3.5 character times marks the end of the message. A
new message can begin after this interval.
Similarly, if a new message begins earlier than 3.5 character
times following a previous message, the receiving device will
consider it a continuation of the previous message. This will set
an error, as the value in the final CRC field will not be valid for
the combined messages. An example message frame is shown
in Table A.1.
Table A.1
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Example Message Frame
Start
Address
Function
Data
CRC
Check
End
T1-T2-T3-T4
8 Bits
8 Bits
n X 8 Bits
16 Bits
T1-T2-T3-T4
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Appendix A: Modbus Protocol
PPC-2000 User’s Guide
Address Field
The address field of a message frame contains eight bits. Valid
slave device addresses are in the range of 0-247 decimal. The
individual slave devices are assigned addresses in the range of
1-247. Address 0 is reserved for broadcast messages. The PPC
controller currently supports only 32 devices. A master
addresses a slave by placing the slave address in the address
field of the message. When the slave sends its response, it
places its own address in this address field of the response to
let the master know which slave is responding.
Function Field
The function code field of a message frame contains eight bits.
Valid codes are in the range of 1-255 decimal. Not all these
codes are applicable to PPC controllers. Current codes are
described in Function Codes on page 276.
When a message is sent from a master to a slave device, the
function code field tells the slave what kind of action to
perform. Examples are to read the On/Off states of a block of
digital inputs or outputs; to read the data contents of a block of
registers; to read the diagnostic status of a controller.
When the slave responds to the master, it uses the function
code field to indicate either a normal (error-free) response or
that some kind of error occurred (called an exception
response). For a normal response, the slave simply echoes the
original function code. For an exception response, the slave
returns a code that is equivalent to the original function code
with its most significant bit set to a logic 1.
For example, a message from the master to slave to read a
block of holding registers would have the following function
code:
0000 0011
Hexadecimal 03
If the slave device takes the requested action without error, it
returns the same code in its response. If an exception occurs, it
returns:
1000 0011
Hexadecimal 83
In addition to its modification of the function code for an
exception response, the slave places a unique code into the data
field of the response message. This tells the master what kind
of error occurred, or the reason for the exception.
The master device’s application program has the responsibility
of handling exception responses. Typical processes are to post
subsequent retries of the message, to try diagnostic messages
to the slave, and to notify operators.
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Appendix A: Modbus Protocol
Data Field
The contents of the data field varies depending on whether
messages originate from a master or slave. Data fields in slave
messages consist of hexadecimal values.
Data fields of master messages contain additional information
which the slave must use to take the action defined by the
function code. This can include items like digital and register
addresses, the quantity of items to be handled, and the count of
actual data bytes in the field.
For example, if the master requests a slave to read a group of
holding registers (function code 03), the data field specifies the
starting register and how many registers are to be read.
If no error occurs, the data field of a response from a slave to a
master contained the data requested. If an error occurs, the
field contains an exception code that the master application can
use to determine the next action to be taken.
The data field can be nonexistent (of zero length) in certain
kinds of messages, where the function code alone specifies the
action.
Error Checking Field
The error checking field contains a 16-bit value implemented
as two 8-bit bytes. The error check value is the result of a
Cyclical Redundancy Check calculation performed on the
message contents.
The CRC field is appended to the message as the last field in
the message. When this is done, the low-order byte of the field
is appended first, followed by the high-order byte. The CRC
high-order byte is the last byte to be sent in the message.
Field Format
When messages are transmitted on standard Modbus serial
networks, each character or byte is sent in this order (left to
right):
Least Significant Bit (LSB)........Most Significant Bit (MSB)
The bit sequence is:
•
With Parity Checking
Start
•
2
3
4
5
6
7
8
Parity
Stop
6
7
8
Stop
Stop
Without Parity Checking
Start
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1
2
3
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4
5
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Appendix A: Modbus Protocol
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Error Checking Methods
Modbus RTU use two kinds of error checking:
•
•
Parity checking
Frame checking (CRC)
Parity checking can be optionally applied to each character,
while the frame checking is applied to the entire message. Both
the character check and message frame check are generated in
the master device and applied to the message contents before
transmission. The slave device checks each character and the
entire message frame during receipt.
The master is configured by the user to wait for a
predetermined time-out interval before aborting the
transaction. This interval is set to be long enough for any slave
to respond normally. If the slave detects a transmission error,
the message will not be acted upon. The slave will not construct
a response to the master. Thus the time-out will expire and
allow the master’s program to handle the error. Note that a
message addressed to a nonexistent slave device will also cause
a time-out.
Parity Checking
Users can configure controllers for Even or Odd Parity
checking, or for No Parity checking. This will determine how
the parity will be set in each character.
If either Even or Odd Parity is specified, the quantity of 1 bits
will be counted in the data portion of each character (8 bits).
The parity bit will then be set to a 0 or 1 to result in an Even or
Odd total of 1 bits.
For example, these eight data bits are contained in an RTU
character frame:
1100 0101
The total quantity of 1 bits in the frame is four. If Even Parity
is used, the frame’s parity bit will be a 0, making the total
quantity of 1 bits still an even number (four). If Odd Parity is
used, the parity bit will be a 1, making an odd quantity (five).
When the message is transmitted, the parity bit is calculated
and applied to the frame of each character. The receiving
device counts the quantity of 1 bits and sets an error if they are
not the same as configured for that device (all devices on the
Modbus network must be configured to use the same parity
check method).
Note that parity checking can only detect an error if an odd
number of bits are picked up or dropped in a character frame
during transmission. For example, if Odd Parity checking is
used, and two 1 bits are dropped from a character containing
three 1 bits, the result is still an odd count of 1 bits.
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Appendix A: Modbus Protocol
If No Parity checking is specified, no parity bit is transmitted
and no parity check can be made. An additional stop bit is
transmitted to fill out the character frame.
CRC Checking
All messages include an error-checking field that is based on a
Cyclical Redundancy Check (CRC) method. The CRC field
checks the contents of the entire message. It is applied
regardless of any parity check method used for the individual
characters of the message.
The CRC field is two bytes, containing a 16-bit binary value.
The CRC value is calculated by the transmitting device, which
appends the CRC to the message. The receiving device
recalculates a CRC during receipt of the message, and
compares the calculated value to the actual value it received in
the CRC field. If the two values are not equal, an error results.
The CRC is started by first pre-loading a 16-bit register to all
1’s. Then a process begins of applying successive 8-bit bytes of
the message to the current contents of the register. Only the
eight bits of data in each character are used for generating the
CRC. Start and stop bits, and the parity bit if one is used, do
not apply to the CRC.
During generation of the CRC, each 8-bit character is exclusive
ORed with the register contents. Then the result is shifted in
the direction of the least significant bit (LSB), with a 0 filled
into the most significant bit (MSB) position. The LSB is
extracted and examined. If the LSB was a 1, the register is then
exclusive ORed with a preset, fixed value (A001 hex). If the
LSB was a 0, no exclusive OR takes place.
This process is repeated until eight shifts have been performed.
After the last shift, the next 8-bit byte is exclusive ORed with
the register’s current value, and the process repeats for eight
more shifts as described above. The final contents of the
register, after all the bytes of the message have been applied,
is the CRC value.
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Appendix A: Modbus Protocol
PPC-2000 User’s Guide
Function Codes
The listing below shows the function codes supported by the
PPC controllers. Codes are listed in decimal.
Table A.2
Function Codes
Code
Decimal
Name
01
Read Coil Status
02
Read Input Status
03
Read Holding Registers
04
Read Input Registers
05
Force Single Coil
06
Preset Single Register
08
Diagnostics
15
Force Multiple Coils
16
Preset Multiple Registers
Read Coil Status 01
Reads the On/Off status of discrete outputs (0X references,
coils) in the slave. Broadcast is not supported.
Read Input Status 02
Reads the On/Off status of discrete inputs (1X references) in
the slave. Broadcast is not supported.
Read Holding Registers 03
Reads the binary contents of holding registers (4X references)
in the slave. Broadcast is not supported.
Read Input Registers 04
Reads the binary contents of input registers (3X references) in
the slave. Broadcast is not supported.
Force Single Coil 05
Forces a single coil (0X reference) to either On or OFF. When
broadcast, the function forces the same coil reference in all
attached slaves.
Preset Single Register 06
Presets a value into a single holding register (4X reference).
When broadcast, the function presets the same register
reference in all attached slaves.
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Appendix A: Modbus Protocol
Diagnostics 08
This function provides a series of tests for checking the
communication system between the master and slave, or for
checking various internal error conditions within the slave.
Broadcast is not supported.
The function uses a two-byte Sub-function code field in the
query to define the type of test to be performed. The slave
echoes both the function code and sub-function code in a
normal response.
Most of the diagnostic queries use a two-byte data field to send
diagnostic data or control information to the slave. Some of the
diagnostics cause data to be returned from the slave in a data
field of a normal response.
Force Multiple Coils 15
Forces each coil (0X reference) in a sequence of coils to either
ON or OFF. When broadcast, the function forces the same coil
references in all attached slaves.
Preset Multiple Registers 16
Presets values into the sequence of holding registers (4X
references). When broadcast, the function presets the same
register references an all attached slaves.
The following sections detail the Diagnostics (08)
subfunctions.
Diagnostics Subfunction -- Return Query Data 00
The data passed in the query data field is to be returned (looped
back) in the response. The entire response message should be
identical to the query.
Subfunction
(Response)
Data Field (Query)
00 00
Any
Data Field
Echo Query Data
Diagnostics Subfunction -- Restart Communications
Option 01
The slave’s peripheral port is to be initialized and restarted,
and all of its communications event counters are to be cleared.
If the port is currently in Listen Only Mode, no response is
returned. This function is the only one that brings the port out
of Listen Only Mode. If the port is not currently in Listen Only
Mode, a normal response is returned. This occurs before the
restart is executed.
Subfunction
(Response)
00 01
00 01
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00 00
FF 00
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Data Field
Echo Query Data
Echo Query Data
277
Appendix A: Modbus Protocol
PPC-2000 User’s Guide
Diagnostics Subfunction -- Return Diagnostic Register 02
The contents of the slave’s 16-bit diagnostic register are
returned in the response.
Subfunction
(Response)
00 02
Contents
Data Field (Query)
00 00
Data Field
Diag. Register
Diagnostics Subfunction -- Force Listen Only Mode 04
Forces the addressed slave to its Listen Only Mode for Modbus
communications. This isolates it from the other devices on the
network, allowing them to continue communicating without
interruption from the addressed slave. No response is returned.
When the slave enters its Listen Only Mode, all active
communication controls are turned off. The ready watchdog
timer is allowed to expire, locking the controls off. While in this
mode, any Modbus messages addressed to the salve or
broadcast are monitored, but no actions will be taken and no
responses will be sent.
The only function that will be processed after the mode is
entered will be the Restart Communications Option function
(function code 8, subfunction 1).
Subfunction
(Response)
00 04
Returned
Data Field (Query)
00 00
Data Field
No Response
Diagnostics Subfunction -- Clear Counters 10 (0A Hex)
Clears all Communication Event counters. Counters are also
cleared upon power-up.
Subfunction
(Response)
00 0A
Data Field (Query)
00 00
Data Field
Echo Query Data
Diagnostics Subfunction -- Return Bus Message Count
11 (0B Hex)
The response data field returns the quantity of messages that
the slave has detected on the communications system since its
last restart, clear counters operations, or power-up.
Subfunction
(Response)
00 0B
278
Data Field (Query)
00 00
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Data Field
Total Message Count
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Appendix A: Modbus Protocol
Diagnostics Subfunction -- Return Bus Communication
Error Count 12 (0C Hex)
The response data field returns the quantity of CRC errors
encountered by the slave since its last restart, clear counters
operation, or power-up.
Subfunction
(Response)
00 0C
Data Field (Query)
00 00
Data Field
CRC Error Count
Diagnostics Subfunction -- Return Bus Exception Error
Count 13 (0D Hex)
The response data field returns the quantity of Modbus
exception responses returned by the slave since its last restart,
clear counters operation, or power-up.
Subfunction
(Response)
00 0D
Data Field (Query)
00 00
Data Field
Exception Error Count
Diagnostics Subfunction -- 14 (0E Hex) Return Slave
Message Count
The response data field returns the quantity of messages
addressed to the slave, or broadcast, that the slave has
processed since its last restart, clear counters operation, or
power-up.
Subfunction
(Response)
00 0E
Data Field (Query)
00 00
Data Field
Slave Message Count
Diagnostics Subfunction -- Return Slave No Response
Count 15 (0F Hex)
The response data field returns the quantity of messages
addressed to the slave for which it returned a no response
(neither a normal response nor an exception response), since its
last restart, clear counters operation, or power-up.
Subfunction
(Response)
00 0F
Count
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Data Field (Query)
00 00
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Data Field
Slave No Response
279
Appendix A: Modbus Protocol
PPC-2000 User’s Guide
Examples
Read Examples
The data read must be sequentially located. When reading a
coil rather than a register, the address must be offset by the
location of the bit to read. Table A.3 shows the query and Table
A.4 shows the response:
Table A.3
Sample Packet for Host Query
Function
Start
Address
High
Start
Address
Low
Number
of
Points
High
Number
of
Points
Low
01
04
0B
B9
00
01
E2
0B
Reading loops 4
& 5 (primary) output% of controller
3 (multipoint read)
03
03
18
9F
00
02
F3
67
Reading digital
input 4 to 13,
controller 1
(input status read)
01
01
0B
BB
00
10
4F
C7
Example
Slave
Address
Reading PV of
loop 2 controller 1
(single point read)
Table A.4
Sample Packet for Slave Response
Example
Slave
Address
Function
Byte
Count
Data1
High
Data1
Low
Reading PV of
loop 2 (1600),
controller 1 (single
point read)
01
04
02
06
40
Reading loops 4 &
5 (primary) output% (50%, 60%),
of controller 3
03
03
04
01
F4
Reading digital
input 4 to 13,
controller 1 (input
status read)
01
01
02
08
00
280
CRC
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Data2
High
02
Data2
Low
58
CRC
BB
60
99
67
BE
3C
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Appendix A: Modbus Protocol
Write Examples
The data written is echoed back to the controller. The following
table displays information for sample packet for host
transmission. Table A.5 shows the query and Table A.6 shows
the response.
Table A.5
Sample Packet for Host Query
Example
Slave
Address
Function
Address
High
Address
Low
Data
High
Data
Low
Writing loop 1 PB
(20), controller 4
(single point write)
04
06
0C
1C
00
14
4B
06
Writing digital
output 30 (on),
controller 2
(single coil write)
02
05
0B
D5
FF
00
9F
D5
Table A.6
CRC
Sample Packet for Slave Response
Example
Slave
Address
Function
Address
High
Address
Low
Data
High
Data
Low
Writing loop 1 PB
(20),
controller 4
(single point write)
04
06
0C
1C
00
14
4B
06
Writing digital output 30 (on), controller 2 (single
coil write)
02
05
0B
D5
FF
00
9F
D5
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CRC
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Appendix A: Modbus Protocol
282
PPC-2000 User’s Guide
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B
Appendix B: Declaration of Conformity
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283
Appendix B: Declaration of Conformity
PPC-2000 User’s Guide
Declaration of Conformity
Series PPC-2000
Erklärt, dass das folgende Produkt:
Deutsch
Bezeichnung:
PPC-2000
Modell-Nummern:
PPC–2 (010, 02X*, 040, 05X*, 06X*, oder 07X*),
PPC-AITB, PPC-TB50
*X anstelle einer Nummer 0 to 9
Klassifikation:
Offenes Prozessregelsystem, Installationskategorie II,
Verschmutzungsgrad II
Nennspannung:
12 bis 24 VÎ (DC)
Nennstromverbrauch:
50 VA max.
WATLOW Anafaze
314 Westridge Drive
Watsonville, California 95076 USA
Declares that the following product:
English
Designation:
PPC-2000
Model Numbers:
PPC–2 (010, 02X*, 040, 05X*, 06X*, or 07X*),
PPC-AITB, PPC-TB50
*X denotes any number 0-9
Classification:
Open Type Process Control Equipment,
Installation Category II, Pollution degree II
Rated Voltage:
12 to 24 VÎ (dc)
Rated Power Consumption:
50 VA maximum
Meets the essential requirements of the following European Union Directives by
using the relevant standards show below to indicate compliance.
89/336/EEC Electromagnetic Compatibility Directive
EN 61326:1997 With A1:1998 – Electrical equipment for measurement, control
and laboratory use – EMC requirements (Industrial Immunity, Class A
Emissions).
Equipment is not for use in Class B emission environment without additional filtering.
EN 61000-4-2:1996 With A1, 1998 – Electrostatic Discharge Immunity
EN 61000-4-3:1997 – Radiated Field Immunity
EN 61000-4-4:1995 – Electrical Fast-Transient / Burst Immunity
EN 61000-4-5:1995 With A1, 1996 – Surge Immunity
EN 61000-4-6:1996 – Conducted Immunity
EN 61000-4-11:1994 Voltage Dips, Short Interruptions and Voltage Variations
Immunity
EN 61000-3-2:1995 With A1-3:1999 – Harmonic Current Emissions
EN 61000-3-3:1995 With A1:1998 – Voltage Fluctuations and Flicker
73/23/EEC Low-Voltage Directive
EN 61010-1:1993 With A1:1995 Safety Requirements of electrical equipment
for measurement, control and laboratory use. Part 1: General requirements
déclare que le produit suivant :
Français
Désignation :
PPC-2000
Numéros de modèle :
PPC–2 (010, 02X*, 040, 05X*, 06X*, ou 07X*),
PPC-AITB, PPC-TB50
*X remplace tout chiffre de 0 à 9
Classification :
Appareil de contrôle de procédés,
Catégorie d’installation II, Degré de pollution II
Tension nominale :
12 à 24 VÎ (c.c)
Consommation d’alimentation nominale: 50 VA maximum
Répond aux normes essentielles des directives suivantes de l'Union européenne
en utilisant les standards normalisés ci-dessous qui expliquent les normes
auxquelles répondre :
Directive 89/336/CEE sur la compatibilité électromagnétique
EN 61326:1997 avec A1 :1998 – Matériel électrique destiné à l’étalonnage, au
contrôle et à l’utilisation en laboratoire – Exigences CEM (Immunité
industrielle, Émissions de catégorie A).
Doit être équipé de filtre extérieur pour l'utilisation en classe B.
EN 61000-4-2:1996 Avec A1, 1998 – Immunité aux décharges électrostatiques
EN 61000-4-3:1997 – Immunité aux champs de radiation
EN 61000-4-4:1995 – Immunité contre les surtensions électriques rapides/ Rafale
EN 61000-4-5:1995 avec A1, 1996 – Immunité contre les surtensions
EN 61000-4-6:1996 – Immunité conduite
EN 61000-4-11:1994 Immunité contre les écarts de tension, interruptions courtes
et variations de tension
EN 61000-3-2:1995 avec A1-3 :1999 – Emissions de courant harmoniques
EN 61000-3-3:1995 avec A1 :1998 – Fluctuations et vacillements de tension
Erfüllt die wichtigsten Normen der folgenden Anweisung(en) der Europäischen
Union unter Verwendung des wichtigsten Abschnitts bzw. der wichtigsten
Abschnitte die unten zur Befolgung aufgezeigt werden.
89/336/EEC Elektromagnetische Kompatibilitätsrichtlinie
EN 61326:1997 mit A1:1998 – Elektrisches Gerät für Messung, Kontrolle und
Laborgebrauch – EMV-Anforderungen (Störfestigkeit Industriebereich,
Klasse A Emissionen)
Equipment ist nicht für die Benutzung in Klasse B Emmisionsumgebung ohne
zusätzliche Filter geeignet.
EN 61000-4-2:1996 mit A1, 1998 – Störfestigkeit gegen elektronische Entladung
EN 61000-4-3:1997 – Störfestigkeit gegen Strahlungsfelder
EN 61000-4-4:1995 – Störfestigkeit gegen schnelle Stöße/Burst
EN 61000-4-5:1995 mit A1, 1996 – Störfestigkeit gegen Überspannung
EN 61000-4-6:1996 – Geleitete Störfestigkeit
EN 61000-4-11:1994 Störfestigkeit gegen Spannungsabfall, kurze
Unterbrechungen und Spannungsschwankungen
EN 61000-3-2:1995 mit A1-3:1999 – Harmonische Stromemissionen
EN 61000-3-3:1995 mit A1:1998 – Spannungsfluktationen und Flimmern
73/23/EEC Niederspannungsrichtlinie
EN 61010-1:1993 mit A1:1995 Sicherheitsanforderungen für elektrische
Geräte für Messungen, Kontrolle und Laborgebrauch. Teil 1: Allgemeine
Anforderungen
Declara que el producto siguiente:
Español
Designación:
PPC-2000
Números de modelo:
PPC–2 (010, 02X*, 040, 05X*, 06X*, o 07X*),
PPC-AITB, PPC-TB50
*X representa un número de 0 a 9
Clasificación:
Equipo Para Control de Proceso de Tipo Abierto,
Voltaje nominal 12 a 24 VÎ (CD)
Consumo de energía nominal: 50 VA máximo
Cumple con los requisitos esenciales de las siguientes Directrices de la Unión
Europea mediante el uso de las normas aplicables que se muestran a continuación
para indicar su conformidad.
89/336/EEC Directriz de compatibilidad electromagnética
EN 61326:1997 CON A1:1998.– Equipo eléctrico para medición, control y uso
en laboratorio – Requisitos EMC (Inmunidad industrial, Emisiones Clase A).
Este Equipo no debe ser utilizado en Ambientes de Emisión Clase B sin filtrado
adicional.
EN 61000-4-2:1996 con A1, 1988 – Inmunidad a descarga electrostática
EN 61000-4-3:1997 – Inmunidad a campo radiado
EN 61000-4-4:1995 – Inmunidad a incremento repentino/rápidas fluctuaciones
eléctricas transitorias
EN 61000-4-5:1995 con A1, 1996 – Inmunidad a picos de voltaje o corriente
EN 61000-4-6:1996 – Inmunidad por conducción
EN 61000-4-11:1994 Inmunidad a caídas de voltaje, variaciones y pequeñas
interrupciones de voltaje
EN 61000-3-2:1995 con A1-3:1999 – Emisiones de corriente armónica
EN 61000-3-3:1995 con A1:1998 – Fluctuaciones de voltaje y centelleo.
73/23/EEC Directriz de bajo voltaje
EN 61010-1:1993 con A1:1995 Requisitos de seguridad de equipo eléctric
para medición, control y uso en laboratorio. Parte 1: Requisitos generales
Jim Boigenzahn
Name of Authorized Representative
Watsonville, California, USA
Place of Issue
General Manager
Title of Authorized Representative
February, 2002
Date of Issue
Directive 73/23/CEE sur les basses tensions
EN 61010-1:1993 avec A1 :1995 Normes de sécurité du matériel électrique
pour la mesure, le contrôle et l’utilisation en laboratoire. 1ère partie :
Conditions générales
________________________________________
Signature of Authorized Representative
Doc. # 30029-00
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Glossary
A
B
Alarm
A signal that indicates that the process has
exceeded or fallen below a certain range around
the setpoint. For example, an alarm may indicate
that a process is too hot or too cold. See also:
Deviation Alarm
Failed Sensor Alarm
Global Alarm
High Deviation Alarm
High Process Alarm
Loop Alarm
Low Deviation Alarm
Low Process Alarm
Baud Rate
The rate of information transfer in serial communications, measured in bits per second.
Ambient Temperature
The temperature of the air or other medium that
surrounds the components of a thermal system.
American Wire Gauge (AWG)
A standard of the dimensional characteristics of
wire used to conduct electrical current or signals.
AWG is identical to the Brown and Sharpe
(B&S) wire gauge.
Analog input
A continuously variable signal that is generated
by a process sensor and measured by a controller.
It usually represents a value, such as process variable. Some analog input signals are –10 to 100
mV, 4-20 mA, 0-5Vdc
Analog Output
A continuously variable signal that is generated
to control a process element, such as a heater or
motor speed. Some analog output signals are 020 mA and 0-10Vdc.
Auto Mode
A feature that allows the controller to set PID
control outputs in response to the Process Variable (PV) and the setpoint.
Boolean
A variable with a value of either 1 or 0.
C
Calibration
The comparison of a measuring device (an
unknown) against an equal or better standard.
Channel
The hardware and firmware that determine the
behavior of control and alarm outputs based on
user set parameters and measured feedback.
Closed Loop
A control system that uses a sensor to measure a
process variable and makes decisions based on
that feedback.
Control Action
The response of a control output when the process variable is changed.
Control Loop
A system that affects controlled elements (outputs) either in response to process or user defined
input.
Control Mode
The type of action that a controller uses. For
example, On/Off, time proportioning, PID, Automatic or manual, and combinations of these.
Cool
A control method and association of parameters
organized around maintaining temperature below
ambient.
Current
The rate of flow of electricity. The unit of measure is the ampere (A).
1 ampere = 1 coulomb per second.
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Custom Linear Input
A user-defined process input that represents a
straight line function.
Distributed Zero Crossing (DZC)
A form of digital output control. Similar to burst
fire.
D
E
Deadband
The range through which a variation of the input
produces no noticeable change in the output. In
the deadband, specific conditions can be placed
on control output actions. Operators select the
deadband. It is usually above the heating proportional band and below the cooling proportional
band.
Default Parameters
The programmed instructions that are permanently stored in the microprocessor software.
Derivative Control (D)
The last term in the PID algorithm. Action that
anticipated the rate of change of the process, and
compensates to minimize overshoot and undershoot. Derivative control is an instantaneous
change of the control output in the same direction
as the proportional error. This is caused by a
change in the process variable (PV) that
decreases over the time of the derivative (TD).
The TD is in units of seconds.
Deviation Alarm
Warns that a process has exceeded or fallen
below a certain range around the setpoint.
Digital to Analog Converter (DAC)
A device that converts a numerical input signal to
a signal that is proportional to the input in some
way.
Electromagnetic Interference (EMI)
Electrical and magnetic noise imposed on a system. There are many possible causes, such as
switching ac power on inside the sine wave. EMI
can interfere with the operation of controls and
other devices.
Engineering Units
Selectable units of measure, such as degrees Celsius and Fahrenheit, pounds per square inch,
Newtons per meter, gallons per minute, liters per
minute, cubic feet per minute or cubic meters per
minute.
EPROM
Erasable Programmable, Read-Only Memory
inside the controller.
F
Failed Sensor Alarm
Warns that an input sensor no longer produces a
valid signal. For example, when there are thermocouple breaks, infrared problems or resistance
temperature detector (RTD) open or short failures.
Filter
Filters are used to handle various electrical noise
problems.
Digital I/O
I/O that interfaces to 2 state field devices such
limit switches or solid state relays.
DIN (Deutsche Industrial Norms)
A set of technical, scientific and dimensional
standards developed in Germany. Many DIN
standards have worldwide recognition.
Dip Switch
A set of compact toggle switches used to configure electronic hardware. The toggle switches are
housed in a Dual In-line Package.
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Digital Filter (DF) — A filter that allows the
response of a system when inputs change unrealistically or too fast. Equivalent to a standard
resistor-capacitor (RC) filter
Digital Adaptive Filter — A filter that rejects
high frequency input signal noise (noise spikes).
Heat/Cool Output Filter — A filter that slows
the change in the response of the heat or cool output. The output responds to a step change by
going to approximately 2/3 its final value within
the numbers of scans that are set.
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Glossary
Flags
A program variable with a value of either 1 or 0.
Frequency
The number of cycles over a specified period of
time, usually measured in cycles per second. Also
referred to as Hertz (Hz). The reciprocal is called
the period.
I
Input
Process variable information that is supplied to
the instrument.
Input Scaling
The ability to scale input readings (readings in
percent of full scale) to the engineering units of
the process variable.
G
Gain
The amount of amplification used in an electrical
circuit. Gain can also refer to the Proportional (P)
mode of PID.
Global Alarm
Alarm associated with a global digital output that
is cleared directly from a controller or through a
user interface.
H
Heat
A control method and association of parameters
organized around maintaining temperature above
ambient.
Hertz(Hz)
Frequency, measured in cycles per second.
High Deviation Alarm
Warns that the process is above setpoint, but
below the high process variable. It can be used as
either an alarm or control function.
High Isolation
System used on some PPC-2000 analog input
modules to protect electronic components from
high voltage faults.
High Process Alarm
A signal that is tied to a set maximum value that
can be used as either an alarm or control function.
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Input Type
The signal type that is connected to an input, such
as thermocouple, RTD, linear or process.
Integer
A variable with a potential range of –32,768 to
32,767.
Integral Control (I)
Control action that automatically eliminates offset, or droop, between setpoint and actual process
temperature.
J
Jumper
A removeable connector that acts as a switch
between a set of pins on a circuit board used to
configure electronic hardware.
L
Linear Input
A process input that represents a straight line
function.
Low Deviation Alarm
Warns that the process is below the setpoint, but
above the low process variable. It can be used as
either an alarm or control function.
Low Process Alarm
A signal that is tied to a set minimum value that
can be used as either an alarm or control function.
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M
Manual Mode
A selectable mode that has no automatic control
aspects. The operator sets output levels.
Modbus
Industrial communications protocol developed by
AEG Schneider Automation.
Parity
A communications error checking method in
which the quantity of bits in each byte is determined to be odd or even. If there is a discrepancy
between the transmitter and receiver, a communications error has occurred.
PID
Proportional, Integral, Derivative. A control
mode with three functions: Proportional action
dampens the system response, Integral corrects
for droops, and Derivative prevents overshoot
and undershoot.
Modbus Address
Number that specifies a bit or word register
within a controller’s memory.
Modbus Database Offset
A number which is combined with a parameter’s
first address to locate specific Modbus addresses.
Module
A component of a PPC-2000 system which
attaches and interfaces with other components.
Module I/O Number
Number designating each I/O supported on a
module. For example, a PPC-2021 has 16 analog
inputs; each input on the module has a unique
designation from 1 to 16.
O
Offset
The difference in temperature between the setpoint and the actual process temperature. Offset
is the error in the process variable that is typical
of proportional-only control.
Output
Control signal action in response to the difference
between setpoint and process variable.
Output Type
The form of PID control output, such as Time
Proportioning, Distributed Zero Crossing,
SDAC, or Analog. Also the description of the
electrical hardware that makes up the output.
Pin Number
Generic terminal block identification numbers
which are correlated to module I/O numbers in
terminal block identification tables for wiring.
Polarity
The electrical quality of having two opposite
poles, one positive and one negative. Polarity
determines the direction in which a current tends
to flow.
Process Variable
The parameter that is controlled or measured.
Typical examples are temperature, relative
humidity, pressure, flow, fluid level, events, etc.
The high process variable is the highest value of
the process range, expressed in engineering units.
The low process variable is the lowest value of
the process range.
Proportional (P)
Output effort proportional to the error from setpoint. For example, if the proportional band is
20º and the process is 10º below the setpoint, the
heat proportioned effort is 50%. The lower the
PB value, the higher the gain.
Proportional Band (PB)
A range in which the proportioning function of
the control is active. Expressed in units, degrees
or percent of span.
See PID.
P
Parameters
The programmed instructions and readings that
are stored in a microprocessor software.
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Proportional Control
A control using only the P (proportional) value of
PID control.
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Glossary
Protocol
A set of rules and formats governing a serial or
parallel communication channel.
Pulse Input
Digital pulse signals from devices, such as optical encoders.
R
Range
The area between two limits in which a quantity
or value is measured. It is usually described in
terms of lower and upper limits.
Register
A controller memory location. Registers are
either bit or word values.
Relay
A switching device.
Electromechanical Relay — A power switching
device that completes or interrupts a circuit by
physically moving electrical contacts into contact
with each other. Not recommended for PID control.
S
Serial Communications
A method of transmitting information between
devices by sending all bits serially over a single
communication channel.
RS-232—An Electronics Industries of America
(EIA) standard for interface between data terminal equipment and data communications equipment for serial binary data interchange. This is
usually for communications over a short distance
(50 feet or less) and to a single device.
RS-485—An Electronics Industries of America
(EIA) standard for electrical characteristics of
generators and receivers for use in balanced digital multipoint systems. This is usually used to
communicate with multiple devices over a common cable or where distances over 50 feet are
required.
Setpoint (SP)
The desired value programmed into a controller.
For example, the temperature at which a system
is to be maintained.
— A switching
device with no moving parts that completes or interrupts a circuit electrically.
Soft Bool
A generic Boolean variable which is stored in the
PPC-2000 database and is accessible by AnaWin
or a logic program. Values range from 1 to 0 (true
or false).
Reset
Control action that automatically eliminates offset or droop between setpoint and actual process
temperature.
See also Integral.
Soft Int
A generic integer variable which is stored in the
PPC-2000 database and is accessible by AnaWin
or a logic program. Values are –32,768 to 32,767.
Automatic Reset — The integral function of a
PI or PID temperature controller that adjusts the
process temperature to the setpoint after the system stabilizes. The inverse of integral.
Spread
In heat/cool applications, the +/- difference
between heat and cool. Also known as process
deadband.
RTD (Resistance Temperature Detector/Device)
A sensor that uses the resistance temperature
characteristic to measure temperature. There are
two basic types of RTDs: the wire RTD, which is
usually made of platinum, and the thermistor
which is made of a semiconductor material. The
wire RTD is a positive temperature coefficient
sensor only, while the thermistor can have either
a negative or positive temperature coefficient.
Switch
Dip
A set of compact toggle switches used to configure electronic hardware. The toggle switches are
housed in a Dual In-line Package.
Solid State Relay (SSR)
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Rotary
A switch with multiple dial-in settings used to
configure electronic hardware.
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T
Thermistor
A temperature-sensing device made of semiconductor material that exhibits a large change in
resistance for a small change in temperature.
Thermistors usually have negative temperature
coefficients, although they are also available with
positive temperature coefficients.
Thermocouple (T/C)
A temperature sensing device made by joining
two dissimilar metals. This junction produces an
electrical voltage in proportion to the difference
in temperature between the hot junction (sensing
junction) and the lead wire connection to the
instrument (cold junction).
Tune
To set PID parameters on a closed-loop control
system.
V
Volt (V)
The unit of measure for electrical potential, voltage or electromotive force (EMF).
Voltage (V)
The difference in electrical potential between two
points in a circuit. It’s the push or pressure behind
current flow through a circuit. One volt (V) is the
difference in potential required to move one coulomb of charge between two points in a circuit,
consuming one joule of energy. In other words,
one volt (V) is equal to one ampere of current (I)
flowing through one ohm of resistance (R), or
V=IR.
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